Cover window, method of manufacturing cover window, and display device

Abstract

The present application relates to a cover window, a display device, and a method of manufacturing a cover window. The cover window includes a base layer; a first coating layer on the base layer; and a second coating layer on the first coating layer. The first coating layer directly contacts a first portion of an upper surface of the base layer and exposes a second portion of the upper surface of the base layer, the upper surface of the base layer consisting of the first portion and the second portion, and the second coating layer directly contacts the second portion of the upper surface of the base layer exposed by the first coating layer and an upper surface of the first coating layer.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims priority to Korean Patent Application No. 10-2020-0118774 filed on September 16, 2020, as well as all the benefits accruing therefrom under 35 U.S.C. § 119, the contents of which in its entirety are incorporated herein by reference. TECHNICAL FIELD

[0003] The present application relates to a cover window, a method of manufacturing a cover window, and a display apparatus. BACKGROUND

[0004] A display apparatus for displaying an image is used for various electronic devices such as a smart phone, a tablet PC, a digital camera, a notebook computer, a navigator, and a television, which provide an image to a user. The display apparatus includes a display panel for generating and displaying an image and a transparent cover window for covering a display surface of the display panel.

[0005] The cover window is used to protect the display panel from external impact and scratches applied during use. Typical materials of the cover window are glass and plastic. In particular, when the cover window is made of plastic, in order to properly perform a protection function of the display panel, the strength of the cover window can be increased by forming a hard coat layer on a surface of the plastic. SUMMARY

[0006] An aspect of the present application is to provide a cover window having improved reliability.

[0007] Another aspect of the present application is to provide a display apparatus including a cover window having improved reliability.

[0008] Still another aspect of the present application is to provide a method of manufacturing a cover window having improved reliability.

[0009] According to an embodiment, the cover window includes a base layer, a first coating layer on the base layer, and a second coating layer on the first coating layer. The first coating layer directly contacts a first portion of an upper surface of the base layer and exposes a second portion of the upper surface of the base layer, the upper surface of the base layer consisting of the first portion and the second portion, and the second coating layer directly contacts the second portion of the base layer exposed by the first coating layer and an upper surface of the first coating layer.

[0010] According to another embodiment, the display apparatus includes a display panel, and a cover window on the display panel, wherein the cover window includes a base layer disposed on the display panel, a first coating layer on the base layer, and a second coating layer on the first coating layer. The first coating layer directly contacts a first portion of the base layer and exposes a second portion of the base layer, an upper surface of the base layer consisting of the first portion and the second portion, and the second coating layer directly contacts the second portion of the base layer exposed by the first coating layer and the first coating layer.

[0011] According to still another embodiment, a method of manufacturing a cover window includes forming a raw first coating layer on a raw sheet by a primary coating; dividing both the raw sheet and the raw first coating layer to form a divided sheet and a divided first coating layer, respectively; primary processing the divided sheet and the divided first coating layer on the divided sheet to form a primary-processed divided sheet and a primary-processed first coating layer; forming a second coating layer on the primary-processed divided sheet and the primary-processed first coating layer by a secondary coating to form a secondary-coated divided sheet; and secondary processing the secondary-coated divided sheet.

[0012] However, aspects of the present application are not limited to the aspects set forth herein. The above and other aspects of the present application will become more apparent by describing in detail the following embodiments of the present application given for the purpose of general BRIEF DESCRIPTION OF DRAWINGS

[0013] The above and other aspects and features of the present application will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings, in which:

[0014] Figure 1 is a perspective view of a display apparatus according to an embodiment;

[0015] Figure 2 is an exploded perspective view of a display apparatus according to an embodiment;

[0016] Figure 3 is a sectional view taken along line I-I' of Figure 1

[0017] Figure 4 is a sectional view of a cover window according to an embodiment;

[0018] Figure 5 is a flowchart illustrating a method of manufacturing a cover window according to an embodiment;

[0019] Figures 6 to 8 is a perspective view of a process step of a method of manufacturing a cover window according to an embodiment;

[0020] Figure 9 is a sectional view taken along line II-II' of Figure 8

[0021] Figures 10 to 12 is a perspective view of a process step of a method of manufacturing a cover window according to an embodiment. DETAILED DESCRIPTION

[0022] ​​The specific structure and function described herein for the embodiments of the present application are for the purpose of illustrating the embodiments of the present application only. The present application can be practiced in a variety of different forms and should not be limited to only the embodiments described herein. Therefore, the embodiments of the present application are only for illustrative purposes and should not be construed as limiting the present application. That is, the present application is defined only by the scope of the claims.

[0023] It should be understood that when an element is referred to as being "associated with" another element, such as "coupled" or "connected" to another element, it can be directly coupled or directly connected to the other element, or one or more intervening elements can exist between them. In contrast, it should be understood that when an element is referred to as being "directly associated with" another element, such as "directly coupled" or "directly connected" to another element, no intervening elements exist. Other expressions describing the relationship between elements, such as "between," "directly between," "adjacent to," or "directly adjacent to," should be interpreted in the same way.

[0024] Throughout the specification, the same reference numerals will be used to designate the same or similar components.

[0025] It should be understood that, although the terms "first," "second," "third," etc. can be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Therefore, "a first element," "a first component," "a first region," "a first layer," or "a first section" discussed below can be called a second element, a second component, a second region, a second layer, or a second section.

[0026] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, "a," "an," "the," and "at least one" are not intended to refer to a quantity of, but rather to include the singular and the plural, unless the context clearly indicates otherwise. For example, "a member" has the same meaning as "at least one member," unless the context clearly indicates otherwise. "At least one" should not be construed as limiting "one" or "a." "Or" means "and / or." As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms "comprises" and / or "comprising," or "includes" and / or "including" when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and / or groups thereof.

[0027] In addition, relative terms such as "lower" or "bottom" and "upper" or "top" can be used herein to describe one element's or feature's relationship to another element or feature as illustrated in the figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures. For example, if the device in one of the figures is turned over, elements described as being on the "lower" side of other elements would then be oriented on the "upper" sides of the other elements. The exemplary term "lower" can therefore encompass both an orientation of "lower" and "upper," depending on the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as "below" or "beneath" other elements would then be oriented "above" the other elements. The exemplary term "below" or "beneath" can therefore encompass both an orientation of above and below.

[0028] As used herein, "about" or "approximately" includes the stated value and the range of values that would be expected by a person of ordinary skill in the art to be within the acceptable deviation of the particular value, as determined by the measurement and the error associated with the measurement of the particular quantity (i.e., the limitations of the measurement system). For example, "about" can mean within one or more standard deviations, or within ±30 percent (30%), ±20%, ±10%, or ±5% of the stated value.

[0029] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0030] Exemplary embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and / or tolerances, are to be expected. Thus, embodiments described herein are not to be construed as being limited to the particular shapes of regions as illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as flat can often have rough and / or nonlinear features. Moreover, sharp angles that are illustrated can be rounded. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region and are not intended to limit the scope of the present claims.

[0031] Embodiments of the present application will be described below with reference to the accompanying drawings.

[0032] Figure 1 is a perspective view of a display device according to an embodiment, Figure 2 is an exploded perspective view of a display device according to an embodiment, and Figure 3 is a cross-sectional view taken along Figure 1 line I-I' of FIG. 1.

[0033] Referring to Figures 1 to 3 , a display device 10 according to an embodiment includes a cover window 100, a display panel 300, a display circuit board 310, a display driver 320, a lower frame 600, a main circuit board 700, and a lower cover 900.

[0034] In this specification, "upper", "over", "top", "upper side", or "upper surface" refer to a side with respect to the display panel 300 on which the cover window 100 is disposed, i.e., one side of the third direction DR3, and "lower", "under", "bottom", "lower side", or "lower surface" refer to a side with respect to the display panel 300 on which the lower frame 600 is disposed, i.e., the other side of the third direction DR3. In addition, "left", "right", "up", and "down" refer to directions when the display panel 300 is viewed from a plane defined by the first direction DR1 and the second direction DR2, i.e., a plan view. For example, "left" refers to the other side of the first direction DR1, "right" refers to one side of the first direction DR1, "up" refers to one side of the second direction DR2, and "down" refers to the other side of the second direction DR2.

[0035] The display device 10 may have a rectangular shape in the plan view (i.e., the view on the third-direction DR3). For example, as Figure 1 and Figure 2 As shown, the display device 10 may have a rectangular planar shape, having a short side (i.e., a horizontal side) in a first direction DR1 (i.e., the X-axis direction) and a long side (i.e., a vertical side) in a second direction DR2 (i.e., the Y-axis direction). The edge where the short side in the first direction DR1 intersects the long side in the second direction DR2 may have a rounded shape with a predetermined curvature or a right-angled shape. The planar shape of the display device 10 according to the present invention is not limited to a rectangular shape, and in another embodiment it may be formed as another polygonal shape, a circular shape, or an elliptical shape.

[0036] The display device 10 may include a first region D1 formed as flat and a second region D2 extending from the left and right sides of the first region D1. The second region D2 may be flat or curved. When the second region D2 is flat, the angle formed by each of the first region D1 and the second region D2 may be an obtuse angle. When the second region D2 is curved, the second region D2 may have a constant curvature or a variable curvature.

[0037] Despite Figure 1 The diagram shows that the second region D2 extends from opposite sides of the first region D1 along the first direction DR1, but the invention is not limited thereto. That is, in another embodiment, the second region D2 may extend from only one of the opposite sides of the first region D1 along the first direction DR1. Alternatively, in addition to the opposite sides of the first region D1 along the first direction DR1, the second region D2 may extend from at least one of the opposite sides along the second direction DR2. Hereinafter, the case where the second region D2 is disposed on the opposite side of the display device 10 along the first direction DR1 will be described primarily.

[0038] A cover window 100 can be disposed on the display panel 300 to cover the upper surface of the display panel 300. Therefore, the cover window 100 can be used to protect the upper surface of the display panel 300. Figure 3 As shown, the cover window 100 can be attached to the display panel 300 via a first adhesive member 510. The first adhesive member 510 can be an optically clear adhesive (“OCA”) film or an optically clear resin (“OCR”) film.

[0039] The cover window 100 can include a light-transmissive area DA 100 corresponding to the display panel 300 and a light-blocking area NDA 100 corresponding to an area other than the display panel 300. The cover window 100 can be disposed in the first area D1 and the second area D2. The light-transmissive area DA 100 can be disposed in a portion of the first area D1 and a portion of the second area D2. The light-blocking area NDA 100 can be non-transparent. Alternatively, the light-blocking area NDA 100 can be a decorative layer having a pattern that a user can see when an image is not displayed. For example, a company logo such as "SAMSUNG" or various characters can be patterned on the light-blocking area NDA 100. Furthermore, the light-blocking area NDA 100 can be provided with a plurality of holes HH for exposing a front camera, a front speaker, an infrared sensor, an iris recognition sensor, an ultrasonic sensor, an illuminance sensor, etc., but the present application is not limited thereto. For example, in another embodiment, some or all of the front camera, the front speaker, the infrared sensor, the iris recognition sensor, the ultrasonic sensor, and the illuminance sensor can be installed in the display panel 300. In this case, some or all of the plurality of holes HH can be omitted.

[0040] The cover window 100 can be made of plastic. The cover window 100 can be flexible.

[0041] Although not shown, a touch sensing unit can also be disposed between the cover window 100 and the display panel 300. The touch sensing unit can be disposed between the cover window 100 and the display panel 300. The touch sensing unit can be disposed in the first area D1 and the second area D2. Accordingly, the touch sensing unit can sense a touch of a user in the second area D2 as well as the first area D1.

[0042] When the touch sensing unit is further disposed, the touch sensing unit can be attached to a lower surface of the cover window 100 by the first adhesive member 510. The touch sensing unit can be additionally provided with a polarizing film thereon to prevent deterioration of visibility due to reflection of external light. In this case, the polarizing film can be attached to the lower surface of the cover window 100 by the first adhesive member 510.

[0043] The touch sensing unit is a unit for sensing a touch position of a user, and can be implemented as a capacitive type such as a self-capacitance type or a mutual-capacitance type. When the touch sensing unit is implemented as the self-capacitance type, the touch sensing unit can include only a touch driving electrode, but when the touch sensing unit is implemented as the mutual-capacitance type, the touch sensing unit can include both a touch driving electrode and a touch sensing electrode. Hereinafter, the touch sensing unit will be described assuming that the touch sensing unit is implemented as the mutual-capacitance type.

[0044] The touch sensing unit can be of a panel type or a film type. In this case, the touch sensing unit can be attached to the thin encapsulation film of the display panel 300 by a second adhesive member. The adhesive member can be an optical clear adhesive (OCA) film or an optical clear resin (OCR) film.

[0045] Alternatively, the touch sensing unit can be integrally formed with the display panel 300. In this case, the touch driving electrodes and the touch sensing electrodes of the touch sensing unit can be disposed on the thin encapsulation film of the display panel 300.

[0046] The display panel 300 can be disposed under the touch sensing unit. The display panel 300 can be disposed to overlap the light-transmissive area DA100 of the cover window 100. The display panel 300 can be disposed in the first area D1 and the second area D2. Accordingly, the image of the display panel 300 can be seen not only in the first area D1 but also in the second area D2.

[0047] The display panel 300 can be a light-emitting display panel including light-emitting elements. Examples of the display panel 300 can include an organic light-emitting display panel using an organic light-emitting diode, a micro light-emitting diode display panel using a micro LED, or a quantum dot light-emitting diode display panel using a quantum dot light-emitting diode.

[0048] The display circuit board 310 can be attached to one side of the display panel 300. Specifically, one side of the display circuit board 310 can be attached to pads disposed on one side of the display panel 300 using an anisotropic conductive film. The display circuit board 310 can be bent toward the lower surface of the display panel 300.

[0049] The display driver 320 outputs signals and voltages for driving the display panel 300 through the display circuit board 310. The display driver 320 can be formed as an integrated circuit and mounted on the display circuit board 310, but the present application is not limited thereto. For example, in another embodiment, the display driver 320 can be directly attached to the substrate of the display panel 300. In this case, the display driver 320 can be attached to the upper surface or the lower surface of the display panel 300.

[0050] The panel-under member 400 can be disposed under the display panel 300. The panel-under member 400 can be attached to the lower surface of the display panel 300 by a second adhesive member 520. The second adhesive member 520 can be an optical clear adhesive (OCA) film or an optical clear resin (OCR) film.

[0051] The panel-under member 400 can include at least one of a light-absorbing member for absorbing external light, a cushioning member for absorbing external impact, a heat-dissipating member for effectively dissipating heat of the display panel 300, and a light-blocking layer for blocking external light.

[0052] A light absorbing member can be disposed under the display panel 300. The light absorbing member inhibits transmission of light to prevent components disposed under the light absorbing member (e.g., the display circuit board 310, etc.) from being observed from above (i.e., in a plan view) the display panel 300. The light absorbing member can include a light absorbing material such as a black pigment or dye.

[0053] A buffer member can be disposed under the light absorbing member. The buffer member absorbs external impact to prevent the display panel 300 from being damaged. The buffer member can be a single layer or multiple layers. For example, the buffer member can include or be formed of a polymer resin such as polyurethane, polycarbonate, polypropylene, or polyethylene, or the buffer member can include or be formed of an elastic material such as rubber, a polyurethane material, or a sponge formed by foaming an acrylic material. The buffer member can be a cushion layer.

[0054] A heat dissipation member can be disposed under the buffer member. The heat dissipation member can include a first heat dissipation layer including graphite or carbon nanotubes and a second heat dissipation layer capable of blocking electromagnetic waves and formed of a metal thin film of copper, nickel, ferrite, or silver having excellent heat conductivity.

[0055] A lower frame 600 can be disposed under the panel lower member 400. The lower frame 600 can include synthetic resin, metal, or both synthetic resin and metal.

[0056] The lower frame 600 can be provided with a first camera hole CMH1 in which the camera device 720 is inserted, a battery hole BH through which heat is discharged from the battery, and a cable hole CAH through which the second connection cable 314 connected to the display circuit board 310 passes. In particular, the cable hole CAH can be disposed close to an edge (e.g., a right edge) of the lower frame 600. Also, the lower frame 600 is disposed under the panel lower member 400 of the display panel 300.

[0057] A main circuit board 700 can be disposed under the lower frame 600. The main circuit board 700 can be a printed circuit board or a flexible printed circuit board.

[0058] The main circuit board 700 can include a main processor 710, a camera device 720, and a main connector 730. The main processor 710 and the main connector 730 can be disposed on a lower surface of the main circuit board 700 facing the lower cover 900. The camera device 720 can be disposed on both an upper surface and a lower surface of the main circuit board 700.

[0059] The main processor 710 can control all functions of the display device 10. For example, the main processor 710 can output image data to the display driver 320 of the display circuit board 310 so that the display panel 300 displays an image. The main processor 710 can be an application processor, a central processing unit, or a system chip including an integrated circuit.

[0060] The camera device 720 processes an image frame (such as a still image or a moving image) obtained by an image sensor in a camera mode and outputs the processed image frame to the main processor 710.

[0061] The second connection cable 314 passing through the cable hole CAH of the lower frame 600 can be connected to the main connector 730 provided on the lower surface of the main circuit board 700 through a gap between the frame 600 and the main circuit board 700. Accordingly, the main circuit board 700 can be electrically connected to the display circuit board 310.

[0062] In addition, the main circuit board 700 can further be provided with a mobile communication module capable of transmitting and receiving a radio signal to and from at least one of a base station, an external terminal, and a server. The radio signal can include various types of data depending on a voice signal, a video call signal, or a text / multimedia message transmission / reception. In addition, the main circuit board 700 can further be provided with a sound output device capable of outputting sound and a vibration device capable of generating vibrations for haptic implementation.

[0063] The lower cover 900 can be disposed under the lower frame 600 and the main circuit board 700. The lower cover 900 can be coupled and fixed to the lower frame 600. The lower cover 900 can form a lower surface appearance of the display device 10. The lower cover 900 can include plastic and / or metal.

[0064] The lower cover 900 can be provided with a second camera hole CMH2 into which the camera device 720 is inserted to protrude outward. The position of the camera device 720 and the positions of the first and second camera holes CMH1 and CMH2 corresponding to the camera device 720 are not limited to the embodiment shown in the drawings.

[0065] The cover window 100 can further extend outward from the side surface of the display panel 300. In other words, the cover window 100 can completely cover the display panel 300 and can further extend outward from the side surface of the display panel 300.

[0066] Cover window 100 may include curved sides. Therefore, the aesthetics of the display device 10 can be improved. Cover window 100 including curved sides is susceptible to external impacts. As mentioned above, cover window 100 comprises a flexible material, and flexible materials are easily damaged (such as scratches) by external impacts. Cover window 100 according to an embodiment may also include a hard coating on its outer surface. (Refer to...) Figure 4 Describe its details.

[0067] Figure 4 This is a cross-sectional view of the cover window according to the implementation method.

[0068] refer to Figure 4 According to the embodiment, the cover window 100 may include a base layer 110, a first coating layer 120 on the base layer 110, and a second coating layer 130 on the first coating layer 120.

[0069] The base layer 110 can provide the areas where the coatings 120 and 130 of the cover window 100 are to be applied. The base layer 110 may include the material of the cover window 100, such as a flexible material.

[0070] The cover window 100 may have curved side surfaces. The base layer 110 may have a cross-sectional shape substantially the same as that of the cover window 100.

[0071] Specifically, such as Figure 3 and Figure 4 As shown, the base layer 110 may include a first surface 110a that contacts the first adhesive member 510 and faces the display panel 300, and a second surface 110b that faces away from the first surface 110a and is coated with the first coating 120. The first surface 110a and the second surface 110b may extend along a first direction DR1. The first surface 110a and the second surface 110b may be parallel to each other, but the invention is not limited thereto. The length of the first surface 110a in the first direction DR1 may be longer than the length of the second surface 110b in the first direction DR1.

[0072] The base layer 110 can include a third surface between the first surface 110a and the second surface 110b. The third surface can include another side sub-surfaces 110c1 and 110d1 at the other side (e.g., left side) in the first direction DR1 and connecting the first surface 110a and the second surface 110b and one side sub-surfaces 110c2 and 110d2 at the one side (i.e., right side) in the first direction DR1 and connecting the first surface 110a and the second surface 110b. The other side sub-surfaces 110c1 and 110d1 and the one side sub-surfaces 110c2 and 110d2 can divide the base layer 110 into equal segments in the first direction DR1 and can be symmetrical to each other with respect to a bisector extending in the third direction DR3 and crossing the center of the base layer 110. Components included in the other side sub-surfaces 110c1 and 110d1 and components included in the one side sub-surfaces 110c2 and 110d2 can be symmetrical to each other with respect to the bisector. Hereinafter, a description will be made based on the other side sub-surfaces 110c1 and 110d1. Also, specifically, when the other side sub-surfaces 110c1 and 110d1 are not required to be distinguished from the one side sub-surfaces 110c2 and 110d2 in explaining the other side sub-surfaces 110c1 and 110d1, the other side sub-surfaces 110c1 and 110d1 are referred to as the third surface.

[0073] The cross-sectional shape of the third surface 110c1 and 110d1 can include at least two different shapes. For example, the cross-sectional shape of the third surface 110c1 and 110d1 can include a curved shape and a linear shape. As used herein, the curved shape can be a curved surface having a constant curvature, but is not limited thereto, and can be a curved surface having various curvatures.

[0074] The third surface 110c1 and 110d1 can include a first portion 110c1 connected to the second surface 110b and a second portion 110d1 connecting the first portion 110c1 and the first surface 110a.

[0075] The first portion 110c1 can have a curved shape, and the second portion 110d1 can have a linear shape extending along the third direction DR3. As will be described later, the above-described cross-sectional shape of the base layer 110 can be formed by a computer numerical control ("CNC") device.

[0076] In some embodiments, the above-described cross-sectional shape of the base layer 110 can be formed by a laser.

[0077] The first coating layer 120 can be disposed on the second surface 110b of the base layer 110 and a portion of the first portion 110c1. The first coating layer 120 can be directly disposed on (i.e., directly contact) the second surface 110b of the base layer 110 and a portion of the first portion 110c1.

[0078] The first coating layer 120 can expose another portion of the first portion 110c1 of the base layer 110 and the second portion 110d1 of the base layer 110.

[0079] In an embodiment, for example, the first coating layer 120 can include an organic material such as a UV-curable acrylate resin or a UV-curable epoxy resin.

[0080] In an embodiment, the first coating layer 120 can include an inorganic material in addition to the above-described organic material. Examples of the inorganic material can include, but are not limited to, nano-silica sol.

[0081] In an embodiment, the first coating layer 120 can be made of a hybrid organic / inorganic material including the above-described organic material and the above-described inorganic material. The first coating layer 120 can have a pencil hardness of HB or more.

[0082] Although it is illustrated in FIG. 1A that the first coating layer 120 is a single layer, the present disclosure is not limited thereto, and the first coating layer 120 can be formed as multiple layers such as a double layer, a triple layer, and a quadruple layer. Figure 4 The first coating layer 120 can be used to enhance the strength (i.e., improve impact resistance) of the cover window 100. For example, when an impact is applied to the cover window 100, the first coating layer 120 can function to prevent damage to the base layer 110 by offsetting stress generated in the base layer 110 by the impact. The first coating layer 120 can absorb impact energy. The thickness of the first coating layer 120 in the third direction DR3 (i.e., the thickness direction) can be set in consideration of the above-described impact resistance improvement function.

[0083] The first coating layer 120 can have a first thickness t1 in the third direction DR3. For example, the first thickness t1 can be a thickness of about 20 micrometers (µm) to 40 µm. When the thickness t1 of the first coating layer 120 is equal to or greater than about 20 µm, the first coating layer 120 can function to appropriately enhance the strength of the cover window 100. When the thickness t1 of the first coating layer 120 is less than about 40 µm, the occurrence of yellowing of the cover window 100 can be prevented in advance.

[0084] The first coating layer 120 can have a first thickness t1 in the third direction DR3. For example, the first thickness t1 can be a thickness of about 20 micrometers (µm) to 40 µm. When the thickness t1 of the first coating layer 120 is equal to or greater than about 20 µm, the first coating layer 120 can function to appropriately enhance the strength of the cover window 100. When the thickness t1 of the first coating layer 120 is less than about 40 µm, the occurrence of yellowing of the cover window 100 can be prevented in advance.

[0085] On the second surface 110b of the base layer 110, the first thickness t1 of the first coating layer 120 can have a deviation of 10% or less. As used herein, the first thickness t1 of the first coating layer 120 having a deviation of 10% or less means that the thickness of the first coating layer 120 on the second surface 110b is substantially uniform.

[0086] The small thickness deviation of the first coating layer 120 for each region can mean that the first coating layer 120 can have a small hardness deviation for each region. In other words, as in one embodiment, the first thickness t1 of the first coating layer 120 has a deviation of 10% or less on the second surface 110b, so that the first coating layer 120 can have a small hardness variation for each region on the second surface 110b.

[0087] The first coating layer 120 can be formed by slit coating. In some embodiments, the first coating layer 120 can be formed using bar coating, spin coating, spray coating, etc.

[0088] The second coating layer 130 can be disposed on the base layer 110. The second coating layer 130 can be disposed on the first coating layer 120 and the first portions 110c1 and 110d1 of the third surfaces 110c1 and 110d1. The second coating layer 130 can contact the upper surface and the side surface of the first coating layer 120, respectively, and can directly contact the upper surface of another portion of the first portion 110c1 exposed by the first coating layer 120. For example, the second coating layer 130 can include an organic material such as a UV-curable acrylate resin or a UV-curable epoxy resin. In an embodiment, the second coating layer 130 can include an inorganic material in addition to the above-described organic material. Examples of the inorganic material can include, but are not limited to, nano-silica sol.

[0089] In an embodiment, the second coating layer 130 can be made of a hybrid organic / inorganic material including the above-described organic material and the above-described inorganic material. The second coating layer 130 can have a pencil hardness of HB or more.

[0090] Although it is shown in Figure 4 that the second coating layer 130 is a single layer, the present application is not limited thereto, and the second coating layer 130 can be formed as multiple layers such as double layers, triple layers, and quadruple layers.

[0091] Similar to the first coating layer 120, the second coating layer 130 can be used to enhance the strength (i.e., improve impact resistance) of the cover window 100. In addition, the second coating layer 130 can be used to prevent the first coating layer 120 from being peeled off from the base layer 110 by covering the first coating layer 120.

[0092] In other words, the second coating 130 is in direct contact with the first coating 120 and with another portion of the first part 110c1 of the base layer 110 exposed by the first coating 120, thereby preventing the first coating 120 from peeling off from the base layer 110.

[0093] In addition, the second coating 130 can be used to protect the cover window 100 from external impacts (e.g., scratches) (i.e., it is scratch resistant).

[0094] The second coating 130 may have a second thickness t2 on the second surface 110b of the base layer 110 (i.e., on the region overlapping the second surface 110b of the base layer 110 in the thickness direction), and may have a third thickness t3 on the first portion 110c1 of the third surfaces 110c1 and 110d1 of the base layer 110. Each of the second thickness t2 and the third thickness t3 may have a thickness of about 10 μm to 30 μm.

[0095] When each of the second thickness t2 and the third thickness t3 of the second coating 130 is about 10 μm or greater, the second coating 130 can enhance the protective effect of the cover window 100 against external impacts (e.g., scratches) (i.e., it has scratch resistance). When each of the second thickness t2 and the third thickness t3 of the second coating 130 is about 30 μm or less, yellowing of the cover window 100 can be prevented in advance.

[0096] According to an embodiment, since the maximum value of the third thickness t3 is the thickness of a portion of the exposed other part of the first portion 110c1 of the base layer 110 covered by the second coating 130, the maximum value of the third thickness t3 can be greater than the maximum value of the second thickness t2, which is the thickness of a portion of the upper surface covering the first coating 120. However, the invention is not limited thereto. The second coating 130 may not be provided on the third surface 110c1 and the second portion 110d1 of the base layer 110. In some embodiments, the second coating 130 may be partially provided on a portion of the second portion 110d1.

[0097] The second coating 130 can be formed by slot coating. In some embodiments, the second coating 130 can be formed by bar coating, spin coating, spray coating, etc.

[0098] The second coating 130 may additionally cover another portion of the third surfaces 110c1 and 110d1 of the base layer 110 exposed by the first coating 120, thereby preventing the cover window 100 from being exposed to the external environment and from being damaged or from yellowing in advance.

[0099] As described above, since the first thickness t1 of the first coating layer 120 has a deviation of 10% or less on the second surface 110b, the first coating layer 120 can have a small hardness variation for each region on the second surface 110b.

[0100] Similar to the first coating layer 120, the second coating layer 130 can enhance the strength of the cover window 100 (i.e., improve impact resistance).

[0101] In addition, the second coating layer 130 can serve to prevent the first coating layer 120 from being peeled off from the base layer 110 by covering the first coating layer 120.

[0102] The second coating layer 130 can protect the cover window 100 from external impact (e.g., scratches) (i.e., have scratch resistance).

[0103] In addition, the second coating layer 130 can also cover another portion of the third surfaces 110c1 and 110d1 of the base layer 110 exposed by the first coating layer 120, thereby preventing the cover window 100 from being exposed to the external environment and being damaged or preventing yellowing from occurring in advance.

[0104] Hereinafter, a method of manufacturing the above-described cover window 100 will be described. In the following embodiments, components identical to those of the foregoing embodiments are denoted by the same reference numerals, and the description thereof will be omitted or simplified.

[0105] Figure 5 is a flowchart illustrating a method of manufacturing a cover window according to an embodiment. Figures 6 to 8 is a perspective view of a process step of a method of manufacturing a cover window according to an embodiment. Figure 9 is a cross-sectional view taken along Figure 8 line II-II' of Figures 10 to 12 is a perspective view of a process step of a method of manufacturing a cover window according to an embodiment.

[0106] Referring to Figure 5 and Figure 6 , an original sheet 110' is prepared.

[0107] The original sheet 110' can become the base layer 110 of the cover window 100 described above in Figure 3 and Figure 4 after being divided.

[0108] The original sheet 110' can include the same material as the above-described base layer 110.

[0109] In an embodiment, for example, the original sheet 110' can include a flexible material.

[0110] As Figure 6As illustrated in FIG. 1, the original sheet 110' can have a rectangular shape. For example, the original sheet 110' can include a long side (i.e., a longitudinal side) extending along a first direction DR1 and a short side (i.e., a transverse side) extending along a second direction DR2. The original sheet 110' can have a large area size. For example, the length of the long side of the original sheet 110' can be about 1700 millimeters (mm), and the length of the short side thereof can be about 1270 mm, but the present disclosure is not limited thereto.

[0111] Subsequently, referring to Figure 6 and Figure 7 , a primary coating is performed on the original sheet 110' to form an original first coating 120' (S10).

[0112] Specifically, the original first coating 120' can include the same material as the first coating 120 described above in Figure 4 . For example, the original first coating 120' can include an organic material such as an ultraviolet-curable acrylate resin or an ultraviolet-curable epoxy resin.

[0113] In an embodiment, the original first coating 120' can include an inorganic material in addition to the above-described organic material. Examples of the inorganic material can include, but are not limited to, nano-silica sol.

[0114] In an embodiment, the original first coating 120' can be made of a hybrid organic / inorganic material including the above-described organic material and the above-described inorganic material. The original first coating 120' can have a pencil hardness of HB or more.

[0115] The original first coating 120' can be formed to cover the entire surface of the original sheet 110'.

[0116] The primary coating of the original first coating 120' can be performed by slit coating. When the primary coating of the original first coating 120' is performed by slit coating, the primary coating is performed on the original sheet 110' having a large area, and thus it is possible to reduce the overall thickness deviation of the original first coating 120'.

[0117] In an embodiment, for example, the thickness deviation of the original first coating 120' on the original sheet 110' can be about 10% or less. Accordingly, the original first coating 120' can have a small hardness variation for each region.

[0118] In some embodiments, the original first coating 120' can be formed using bar coating, spin coating, spray coating, etc.

[0119] Subsequently, referring to Figure 6 , Figure 8 and Figure 9, both the original sheet 110' and the original first coating 120' are divided (S20).

[0120] The dividing of the original sheet 110' and the original first coating 120' can be performed by a computer numerical control (CNC) device.

[0121] In some embodiments, the dividing of both the original sheet 110' and the original first coating 120' can be performed by a laser.

[0122] The divided sheet 110" and the divided first coating 120" can be formed by dividing the original sheet 110' and the original first coating 120', respectively.

[0123] Although Figure 8 Although six divided sheets 110" and six divided first coatings 120" are illustrated, the present application is not limited thereto, and in another embodiment, the number of divided sheets 110" and the number of divided original first coatings 120' can be 2 to 5 or 7 or more, respectively.

[0124] The side surface of the divided sheet 110" and the side surface of the divided first coating 120" on the divided sheet 110" can be aligned with each other. In a plan view, the divided sheet 110" and the divided first coating 120" can have the same size as each other.

[0125] Subsequently, with reference to Figure 5 and Figure 10 The divided sheet 110" and the divided first coating 120" on the divided sheet 110" are primarily processed to form a divided sheet 110'" and a first coating 120 (S30).

[0126] Specifically, the cross-sectional shape of the divided sheet 110'" and the first coating 120 formed by primarily processing the divided sheet 110" and the divided first coating 120" on the divided sheet 110" can be the same as the cross-sectional shape of the base layer 110 and the first coating 120 described above in Figure 4 , except for the protrusions 110p1 and 110p2. The primary processing of the divided sheet 110" and the divided first coating 120" on the divided sheet 110" can be performed by a computer numerical control (CNC) device.

[0127] In some embodiments, the primary processing of the divided sheet 110" and the divided first coating 120" on the divided sheet 110" can be performed by a laser.

[0128] Figure 10The divided sheet 110''' can include a first surface 110a and a second surface 110b facing the first surface 110a and contacting the first coating layer 120. The first surface 110a and the second surface 110b can extend along the first direction DR1. The first surface 110a and the second surface 110b can be parallel to each other, but the present disclosure is not limited thereto. The length of the first surface 110a in the first direction DR1 can be longer than the length of the second surface 110b in the first direction DR1.

[0129] The divided sheet 110''' can further include a third surface between the first surface 110a and the second surface 110b. The third surface can physically connect the first surface 110a and the second surface 110b. The third surface can include one side sub-surface 110c1, 110d1', 110e1, and 110f1 at one side (i.e., left side) in the first direction DR1 and another side sub-surface 110c2, 110d 2' , 110e1, and 110f1 at the other side (or right side) in the first direction DR1. The one side sub-surface 110c1, 110d1', 110e1, and 110f1 and the other side sub-surface 110c2, 110d 2' , 110e1, and 110f1 can divide the divided sheet 110''' into equal segments in the first direction DR1 and can be symmetrical to each other with respect to a bisector extending in the third direction DR3 and crossing the center of the divided sheet 110'''. Hereinafter, when it is not necessary to distinguish the one side sub-surface 110c1, 110d1', 110e1, and 110f1 from the other side sub-surface 110c2, 110d 2' , 110e1, and 110f1, the one side sub-surface 110c1, 110d1', 110e1, and 110f1 is referred to as the third surface. In addition, the divided sheet 110''' further includes protrusions 110p1 and 110p2 defined by the third portion 110e1, the fourth portion 110f1, and a portion of the first surface 110a (to be described later). Even in the case of the protrusions 110p1 and 110p2, specifically, when it is not necessary to distinguish the protrusions 110p1 and 110p2 from each other, the description will be made based on the protrusion 110p1.

[0130] The cross-sectional shape of the third surface 110c1, 110d1', 110e1, and 110f1 can not have a linear shape. For example, the cross-sectional shape of the third surface 110c1, 110d1', 110e1, and 110f1 can include a linear shape and a curved shape.

[0131] The third surfaces 110c1, 110d1', 110e1, and 110f1 can include a first portion 110c1 disposed between the second surface 110b and the first surface 110a and connected to the second surface 110b, a second portion 110d1' disposed between the first portion 110c1 and the first surface 110a and connected to the first portion 110c1, a third portion 110e1 disposed between the second portion 110d1' and the first surface 110a and connected to the second portion 110d1', and a fourth portion 110f1 disposed between the third portion 110e1 and the first surface 110a and connected to the third portion 110e1 and the first surface 110a. The first portion 110c1 can have a curved shape, the second portion 110d1' can have a linear shape extending in the third direction DR3 from an end of the first portion 110c1, the third portion 110e1 can include a linear shape extending to one side (i.e., the left side) of the first direction DR1 from an end of the second portion 110d1', and the fourth portion 110f1 can have a linear shape extending in the third direction DR3 from an end of the third portion 110e1.

[0132] As shown in Figure 10 The protruding portion 110p1 can protrude toward one side of the first direction DR1 based on an extension line of the second portion 110d1' of the divided sheet 110"' in the third direction DR3. The protruding portion 110p1 can be composed of the third portion 110e1, the fourth portion 110f1, and a portion of the first surface 110a. The protruding portion 110p1 can be removed after the second coating is formed.

[0133] The first coating 120 can be disposed on a portion of the second surface 110b and the first portion 110c1 of the divided sheet 110"'. The first coating 120 can be disposed directly on (in direct contact with) a portion of the second surface 110b and the first portion 110c1 of the divided sheet 110"'. The first coating 120 can expose other portions of the third surface of the divided sheet 110"' except for the portion of the first portion 110c1.

[0134] In the method of manufacturing a cover window according to the embodiment, since the primary processing is performed after the primary coating of the original sheet 110' and the division of the original sheet 110', the thickness deviation of the first coating 120 can be greatly reduced compared to when the primary processing is first performed and then the primary coating is performed.

[0135] Subsequently, with reference to Figure 5 and Figure 11 the second coating 130' is formed on the divided sheet 110"' after the primary processing and the first coating 120 by the secondary coating (S40).

[0136] The second coating layer 130' can be formed on the divided sheet 110'" and the first coating layer 120. The second coating layer 130' can be formed on the upper surface and the side surface of the first coating layer 120, the other portion of the first portion 110c1, and the third portion 110e1. The second coating layer 130' can not be formed on the second portion 110d1' or the fourth portion 110f1 extending along the third direction DR3, but the present disclosure is not limited thereto, and a portion of the second coating layer 130' can be formed on the second portion 110d1' or the fourth portion 110f1.

[0137] The second coating layer 130' can be directly formed on the upper surface and the side surface of the first coating layer 120, the other portion of the first portion 110c1, and the third portion 110e1. For example, the second coating layer 130' can include an organic material such as a UV-curable acrylate resin or a UV-curable epoxy resin.

[0138] In an embodiment, the second coating layer 130' can include an inorganic material in addition to the above-described organic material. Examples of the inorganic material can include, but are not limited to, nanosilica sol.

[0139] In an embodiment, the second coating layer 130' can be made of a hybrid organic / inorganic material including the above-described organic material and the above-described inorganic material. The second coating layer 130' can have a pencil hardness of HB or more.

[0140] The second coating layer 130' can even be formed on the protrusion portion 110p1. Thereafter, the second coating layer 130' formed on the protrusion 110p1 can be removed through secondary processing.

[0141] Next, referring to Figure 5 and Figure 12 the divided sheet 110'" is secondarily processed (S50).

[0142] Specifically, the divided sheet 110'" is secondarily processed (S50) to form the cover window 100 described above in Figure 4 .

[0143] The protrusion portion 110p1 of the divided sheet 110'" and the second coating layer 130' on the protrusion portion 110p1 can be removed through secondary processing of the divided sheet 110'" (S50).

[0144] The secondary processing of the divided sheet 110'" (S50) can be performed by a computer numerical control (CNC) device.

[0145] In some embodiments, the secondary processing of the divided sheet 110'" (S50) can be performed by a laser.

[0146] According to the cover window, the display apparatus, and the method of manufacturing a cover window according to the embodiments, the reliability of the cover window can be improved.

[0147] The effects of the present application are not limited to the foregoing, and other various effects are contemplated herein.

[0148] While preferred embodiments of the application have been disclosed in connection with the preferred embodiments of the application for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the application as disclosed in the accompanying claims.

Claims

1. A cover window, comprising: a base layer; a first coating layer on the base layer; and a second coating layer on the first coating layer, wherein the first coating layer directly contacts a first portion of an upper surface of the base layer and exposes a second portion of the upper surface of the base layer, the upper surface of the base layer consists of the first portion and the second portion, and the second coating layer directly contacts the second portion of the upper surface of the base layer exposed by the first coating layer and an upper surface of the first coating layer, wherein the base layer comprises: a first surface; a second surface facing away from the first surface; and a third surface connected to the first surface and the second surface and including a surface inclined downward from the second surface toward the first surface, wherein the upper surface of the base layer includes the second surface and a portion of the third surface, wherein the third surface includes a first part connected to the second surface and a second part between the first part and the first surface, and the first part and the second part have different shapes from each other, wherein the first part includes a curved surface, and the second part includes a flat surface extending along a thickness direction of the base layer, wherein the first coating layer directly contacts a first portion of the second surface of the base layer and the first part of the third surface, and does not directly contact a second portion of the first part of the third surface, the first part consists of the first portion and the second portion of the first part, and the second coating layer directly contacts the second portion of the first part of the third surface. 2.The cover window of claim 1, the first coating layer has a first thickness in a thickness direction of the base layer, and wherein, the first thickness has a deviation of ten percent or less. 3.The cover window of claim 2, the first thickness of the first coating layer is in a range of 20 μm to 40 μm, wherein, the second coating layer has a second thickness in the thickness direction, and the second thickness is in a range of 10 μm to 30 μm. 4.A display device, comprising: a display panel; and a cover window on the display panel, wherein the cover window comprises: a base layer disposed on the display panel; a first coating layer on the base layer; and a second coating layer on the first coating layer, wherein the first coating layer directly contacts a first portion of the base layer and exposes a second portion of the base layer, an upper surface of the base layer consists of the first portion and the second portion, and the second coating layer directly contacts the second portion of the base layer exposed by the first coating layer and the first coating layer, wherein the base layer comprises: a first surface; a second surface facing away from the first surface; and a third surface connected to the first surface and the second surface and including a surface inclined downward from the second surface toward the first surface, wherein the upper surface of the base layer includes the second surface and a portion of the third surface. ​ ​ wherein the third surface includes a first portion connected to the second surface and a second portion between the first portion and the first surface, and the first portion and the second portion have different shapes from each other, wherein the first portion includes a curved surface, and the second portion includes a flat surface extending along a thickness direction of the base layer, wherein the first coating directly contacts a first part of the first portion of the third surface and does not directly contact a second part of the first portion of the third surface, the first portion consists of the first part and the second part of the first portion, and the second coating directly contacts the second part of the first portion of the third surface.

5. The display device according to claim 4, wherein, the cover window further extends to an outside of the display panel.

6. A method of manufacturing a cover window according to any one of claims 1-3, comprising: forming a raw first coating on a raw sheet by primary coating; dividing both the raw sheet and the raw first coating to form a divided sheet and a divided first coating, respectively; primary processing the divided sheet and the divided first coating on the divided sheet to form a primary-processed divided sheet and a primary-processed first coating; forming a second coating on the primary-processed divided sheet and the primary-processed first coating by secondary coating to form a secondary-coated divided sheet; and secondary processing the secondary-coated divided sheet. ​

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