Apparatus for manufacturing display devices

Abstract

An apparatus for manufacturing a display device includes: a deformation unit for deforming a cover window by pressing it, wherein the deformation unit includes: a first mold on which the cover window is disposed; a sleeve configured to be spaced apart from the first mold and linearly movable to the first mold; a second mold inserted into the sleeve and linearly movable to the first mold for deforming a portion of the cover window on the first mold; and a pressing plate for pressing the sleeve and the second mold to the first mold.

Description

[0001] This application is a divisional application of Chinese patent application filed on October 21, 2016, with application number 201610920672.3 and entitled "Method for Manufacturing a Display Device".

[0002] This application claims priority to, and all benefits derived therefrom, Korean Patent Application No. 10-2015-0151094, filed on October 29, 2015, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] One or more embodiments relate to a method of using an apparatus, and more specifically, to a method of manufacturing a display device using a display device manufacturing apparatus. Background Technology

[0004] In recent years, mobile electronic devices have been widely used. These mobile electronic devices typically include not only small electronic devices (such as mobile phones) but also the widely used tablet PCs (“PCs”).

[0005] Mobile electronic devices typically include display devices for providing visual information (such as images or videos) to support various functions. Recently, display devices have become increasingly important in mobile electronic devices as the components used to drive them are being miniaturized, and flexible or foldable display devices that can be bent at a specific angle are also under development. Summary of the Invention

[0006] One or more embodiments include a method for manufacturing a display device that reduces defects in the cover window caused by irregular pressure applied to the cover window during conventional manufacturing methods.

[0007] According to one or more embodiments, a method for manufacturing a display device includes: accommodating a cover window on a first mold; preheating the cover window on the first mold; arranging a sleeve and a second mold on the cover window; and molding the cover window by pressing the sleeve and the second mold toward the first mold.

[0008] According to one embodiment, the step of molding a cover window by pressing a sleeve and a second mold may include: moving a pressing plate to contact the second mold and the sleeve, wherein the second mold and the sleeve may be arranged such that the pressing plate contacts the second mold and the sleeve in sequence when the pressing plate moves to the second mold and the sleeve.

[0009] According to one embodiment, the method may further include: conveying a first mold on which a cover window is disposed.

[0010] According to one embodiment, the step of molding a cover window by pressing a sleeve and a second mold includes heating the cover window.

[0011] According to one embodiment, the method may further include a cooling cover window.

[0012] According to one embodiment, the step of cooling the cover window includes: arranging a pressure plate including a cooler on the sleeve and the second mold.

[0013] According to one embodiment, the second mold can be inserted into the sleeve and moved linearly.

[0014] According to one embodiment, the sleeve can contact the flat portion of the cover window and support the cover window, and the second mold can contact the portion of the cover window to be deformed.

[0015] According to one embodiment, the second mold may include a plurality of sub-molds, and these plurality of sub-molds are configured to move linearly to the portion of the cover window to be deformed.

[0016] According to one embodiment, the width of the second mold in the length direction of the sleeve may be non-constant. Attached Figure Description

[0017] These and / or other features of the embodiments of the present invention will become apparent and more readily understood from the following description of the embodiments in conjunction with the accompanying drawings, in which:

[0018] Figure 1 This is an illustration showing an apparatus for manufacturing a display device according to one embodiment;

[0019] Figure 2 It is shown Figure 1 A cross-sectional view of a portion of a deformable unit of an apparatus for manufacturing a display device;

[0020] Figure 3 It is shown Figure 1 A cross-sectional view of a portion of the cooling unit of an apparatus used to manufacture a display device;

[0021] Figure 4 It is shown by Figure 1 A cross-sectional view of a display device manufactured by the apparatus shown in the diagram.

[0022] Figure 5 Is Figure 4 A plan view of a portion of the display device shown;

[0023] Figure 6 It is along Figure 5 A cross-sectional view of line VV;

[0024] Figure 7 It is shown Figure 1 A cross-sectional view of an alternative embodiment of a modified unit of the apparatus for manufacturing a display device, as shown; and

[0025] Figure 8 It is shown Figure 7 The cross-sectional view of the operating state of the deformable unit shown. Detailed Implementation

[0026] The invention will now be described more fully below with reference to the accompanying drawings, in which various embodiments are illustrated. However, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be sufficient and complete, and will fully convey the scope of the invention to those skilled in the art. The same reference numerals throughout denote the same elements.

[0027] It should be understood that although the terms "first," "second," etc., may be used in this document to describe various components, these components should not be limited to these terms. These terms are only used to distinguish one component from another.

[0028] Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, as used herein. “Or” means “and / or.” As used herein, the term “and / or” includes any and all combinations of one or more of the relevant listed items.

[0029] It will also be understood that the terms “comprises” and / or “comprising”, or “includes” and / or “including”, when used in this specification, indicate the presence of the described features, areas, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, areas, integrals, steps, operations, elements, components, and / or groups thereof.

[0030] It will be understood that when a layer, region, or component is referred to as being "on" another layer, region, or component, it can be formed directly or indirectly on that other layer, region, or component. That is, for example, there can be layers, regions, or components in between.

[0031] 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 common dictionaries) shall be interpreted as having the meaning consistent with their meaning in the context of the relevant art and shall not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0032] Exemplary embodiments are described herein with reference to cross-sectional illustrations, which are schematic diagrams of idealized embodiments. Thus, differences from the illustrated shapes will be anticipated due to, for example, manufacturing techniques and / or tolerances. Therefore, the embodiments described herein should not be construed as limited to the specific shapes of the regions shown herein, but should include deviations in shape due to, for example, manufacturing processes. For example, regions illustrated or described as flat may generally have rough and / or non-linear characteristics. Furthermore, sharp corners shown may be rounded. Therefore, the regions shown in the figures are substantially schematic, and their shapes are not intended to show precise shapes of the regions and are not intended to limit the scope of the claims.

[0033] For ease of description, the dimensions of the components in the figures may be enlarged. In other words, because the dimensions and thicknesses of the parts in the figures are shown arbitrarily for ease of description, the following embodiments are not limited to these.

[0034] In this paper, the x-axis, y-axis, and z-axis are not limited to the three axes of a Cartesian coordinate system and can be interpreted in a broader sense. For example, the x-axis, y-axis, and z-axis can be perpendicular to each other, or they can represent different directions that are not perpendicular to each other.

[0035] In this document, a particular process sequence may be performed differently than the sequence described. For example, two consecutively described processes may be performed substantially simultaneously or in the reverse order of their description.

[0036] Figure 1 This is an illustration of a display device manufacturing apparatus 1 for manufacturing a display device according to one embodiment. Figure 2 It is shown Figure 1 A cross-sectional view of a portion of the deformation unit of the display device manufacturing apparatus 1 shown. Figure 3 It is shown Figure 1 A cross-sectional view of a portion of the cooling unit of the display device manufacturing apparatus 1 shown.

[0037] Reference Figures 1 to 3 One embodiment of the display device manufacturing apparatus 1 may include a loading unit 100, a conveying unit 200, a preheating unit 300, a deformation unit 400, a cooling unit 500, and an unloading unit 600.

[0038] The cover window 10, delivered from the outside, can be supplied to the loading unit 100, and the delivery unit 200 can be installed at the loading unit 100. In this embodiment, the loading unit 100 can control or adjust the external and internal pressures, and the cover window 10 can be delivered to the delivery unit 200 via, for example, a robotic arm (not shown) of the loading unit 100.

[0039] The conveying unit 200 may be mounted to pass through the loading unit 100, preheating unit 300, deformation unit 400, cooling unit 500, and unloading unit 600. In this embodiment, the conveying unit 200 may have one of various configurations. In one embodiment, for example, the conveying unit 200 may include a conveyor belt 210, a plurality of rollers 220, and a roller driver 230. The conveyor belt 210 may contact the plurality of rollers 220 and form a closed loop, and the roller driver 230 may rotate at least one of the plurality of rollers 220. According to an alternative embodiment, the conveying unit 200 may have an air bearing configuration. According to another alternative embodiment, the conveying unit 200 may include a plurality of rollers and a roller driver. According to another alternative embodiment, the conveying unit 200 may include a linear motion guide and a linear driver. In this embodiment, the linear driver may include a linear motor. According to another alternative embodiment, the conveying unit 200 may include a ball screw and a motor for rotating the ball screw. However, the structure of the conveying unit 200 is not limited to the structure described above, and the conveying unit 200 may include any means or structure for accommodating and conveying the first mold 410 described below.

[0040] The preheating unit 300 may include a preheater 310 spaced apart from the conveying unit 200. The preheater 310 may have one of various configurations. In one embodiment, for example, the preheater 310 may include a laser beam irradiation unit for irradiating a laser beam. According to an alternative embodiment, the preheater 310 may be arranged as a coil for providing radiant and convective heat. According to another alternative embodiment, the preheater 310 may have a rod-like or plate-like shape, such as a ceramic heater. However, for ease of description, embodiments in which the preheater 310 has a rod-like shape, such as that of a ceramic heater, will be described in detail below.

[0041] In this implementation, such as Figure 2 As shown, the deformation unit 400 may include a first mold 410, a sleeve 420, a second mold 430, a pressing plate 440, and a driver 450.

[0042] The cover window 10 or its material M may be disposed on the first mold 410. In one embodiment, after the cover window 10 is fully molded, a groove 411 having a shape corresponding to the shape of the cover window 10 may be defined on the surface of the first mold 410. Hereinafter, the groove 411 refers to the uneven portion of the first mold 410 defined by the groove formed on its surface. In this embodiment, a portion of the groove 411 of the first mold 410 may have a specific curvature, and another portion of the groove 411 may be flat. In this embodiment, the shape of the groove 411 of the first mold 410 is not limited thereto and may be varied according to the shape of the cover window 10.

[0043] The cover window 10 can have various shapes. In one embodiment, for example, the two opposite end portions of the cover window 10 can be curved, and the central portion of the cover window 10 can be flat. In this embodiment, the two opposite end portions of the cover window 10 can have different radii of curvature. According to one embodiment, the two opposite end portions of the cover window 10 can have the same radius of curvature. According to an alternative embodiment, the entire cover window 10 can be curved. In this embodiment, the cover window 10 can have a single radius of curvature. According to another alternative embodiment, the cover window 10 can have multiple radii of curvature. For ease of description, embodiments in which the cover window 10 includes two opposite curved end portions having different radii of curvature from each other and a flat central portion will be described in detail below.

[0044] After molding, the cover window 10 as described above may include a flat first cover window (not shown), a second cover window (not shown) extending from the first cover window, and a third cover window (not shown) extending from the first cover window. In this embodiment, after the cover window 10 is molded, the second and third cover windows may correspond to curved portions of the cover window 10, wherein the radii of curvature of the second and third cover windows may be different from each other. In one embodiment, for example, the radius of curvature of the third cover window may be greater than that of the second cover window.

[0045] The groove 411 of the first mold 410 may correspond to the surface of the cover window 10 (e.g., the surface of the first cover window, the surface of the second cover window, and the surface of the third cover window). In one embodiment, the groove 411 may have the same shape as the surface of the cover window 10 (e.g., a combination of the shapes of the first cover window, the second cover window, and the third cover window).

[0046] A sleeve 420 may be disposed on the first cover window. In one embodiment, the sleeve 420 may hold or support the first cover window together with the first mold 410. In this embodiment, the sleeve 420 may press the first cover window.

[0047] Insertion holes 421 and 422 (into which the second mold 430 is inserted) may be defined within the sleeve 420. In one embodiment, insertion holes 421 and 422 may guide the second mold 430 such that the second mold 430 can move linearly. In one embodiment, as... Figure 2 As shown, by preventing the second mold 430 from moving in the horizontal direction and allowing the second mold 430 to move only in the vertical direction, the insertion holes 421 and 422 can restrict the movement of the second mold 430.

[0048] The second mold 430 can mold the cover window 10 into a partially curved shape. In one embodiment, the second mold 430 may be arranged in positions corresponding to the curved portions of the cover window 10 to be molded, wherein the number of second molds 430 may correspond to the number of curved portions of the molded cover window 10. In one embodiment, for example, if the molded cover window 10 includes two curved portions, the deformation unit 400 may include two second molds 430. In an alternative embodiment, if the molded cover window 10 includes three curved portions, the deformation unit 400 may include three second molds 430. In this embodiment, the molded cover window 10 may include multiple curved portions, and the deformation unit 400 may include multiple second molds 430. Hereinafter, for ease of description, terms such as Figure 2 The embodiment shown, in which the molded cover window 10 includes two curved portions and the deformation unit 400 may include two second molds 430, will be described in detail.

[0049] In one embodiment, the second mold 430 may include a first sub-mold 431 at a position corresponding to the location of the second cover window (which is a curved portion of the molded cover window 10). In this embodiment, the second mold 430 may include a second sub-mold 432 at a position corresponding to the location of the third cover window (which is another curved portion of the molded cover window 10).

[0050] In one embodiment, as described above, the first sub-mold 431 and the second sub-mold 432 can be inserted into the sleeve 420 and move linearly. In this embodiment, the insertion holes 421 and 422 of the sleeve 420 may include a first insertion hole 421 and a second insertion hole 422, the first insertion hole 421 being arranged at a position corresponding to the position of the first sub-mold 431, and the second insertion hole 422 being arranged at a position corresponding to the position of the second sub-mold 432. The first insertion hole 421 and the second insertion hole 422 may be arranged to correspond to portions of the first sub-mold 431 and the second sub-mold 432, respectively. In one embodiment, the first insertion hole 421 and the second insertion hole 422 may have a substantially "T" shape.

[0051] In one implementation, such as Figure 2 As shown, the first sub-mold 431 may include a first contact unit 431a and a first pressing portion 431b. In this embodiment, the width of the first contact unit 431a and the width of the first pressing portion 431b, measured along the length direction (e.g., the x-axis direction) of the sleeve 420, may be different from each other. In this embodiment, the width of the first contact unit 431a may be greater than the width of the first pressing portion 431b.

[0052] In this embodiment, the first contact unit 431a and the first pressing part 431b can be connected to each other and form a "T"-shaped structure.

[0053] In an alternative embodiment, the first contact unit 431a and the first pressing portion 431b may be modified to have various shapes. In one embodiment, for example, the first contact unit 431a and the first pressing portion 431b may have a hexahedral shape.

[0054] In one embodiment, the second sub-mold 432 may include a second contact unit 432a, a second pressing portion 432b, and a second protrusion 432c. In this embodiment, the second contact unit 432a and the second pressing portion 432b are the same as or similar to the first contact unit 431a and the first pressing portion 431b, and any repetitive detailed description of them will be omitted.

[0055] In one embodiment, the second protrusion 432c may have a curved surface. In this embodiment, the curved surface of the second protrusion 432c is movable to contact and bend the third cover window. In this embodiment, a portion of the second protrusion 432c may protrude toward the groove 411 of the first mold 410, and thus this portion of the second protrusion 432c may be inserted into the groove 411.

[0056] As described above, the first sub-mold 431 and the second sub-mold 432 can protrude from the sleeve 420 to different heights. In this embodiment, the height of the protruding portions of the first sub-mold 431 and the second sub-mold 432 from the sleeve 420 can be varied according to the radius of curvature of the curved portion of the cover window 10. In one embodiment, for example, the height of the protruding portions of the first sub-mold 431 and the second sub-mold 432 from the sleeve 420 can be proportional to the radius of curvature of the curved portion of the cover window 10. In one embodiment, when the radius of curvature of the molded second cover window is smaller than that of the molded third cover window, such as... Figure 2 As shown, the height of the portion of the first sub-mold 431 protruding from the sleeve 420 may be less than the height of the portion of the second sub-mold 432 protruding from the sleeve 420.

[0057] In one embodiment, the pressing plate 440 may include a first pressing plate 441 and a second pressing plate 442. In this embodiment, the first pressing plate 441 is linearly movable and contacts the sleeve 420 and the second mold 430, pressing the sleeve 420 and the second mold 430 toward the first mold 410. The surfaces of the first pressing plate 441 that contact the sleeve 420 and the second mold 430 may be flat. In one embodiment, the second pressing plate 442 may be arranged to face the surface of the first mold 410.

[0058] According to one embodiment, the first pressing plate 441 may include a first pressing plate body 441a and a first heater 441b, the first pressing plate body 441a contacting the sleeve 420 and the second mold 430, the first heater 441b being disposed or mounted in the first pressing plate body 441a. In this embodiment, the first heater 441b may have a rod-like shape and be inserted into the first pressing plate body 441a. According to an alternative embodiment, the first pressing plate 441 may include a first pressing plate body 441a in which the first heater 441b is not present. In this embodiment, the first heater 441b may be separately mounted outside the first pressing plate body 441a. However, for ease of description, embodiments in which the first pressing plate 441 includes the first pressing plate body 441a and the first heater 441b will be described in detail below.

[0059] In one embodiment, the first pressing plate 441 can cause the second mold 430 and the sleeve 420 to move linearly in sequence and contact and press the second mold 430 and the sleeve 420. In this embodiment, the first pressing plate 441 can contact and press the second sub-mold 432, the first sub-mold 431 and the sleeve 420 in a predetermined order determined based on its height relative to the first mold 410 (e.g., in the order of the second sub-mold 432, the first sub-mold 431 and the sleeve 420).

[0060] According to one embodiment, the second pressing plate 442 may include a second pressing plate body 442a and a second heater 442b. In this embodiment, the second pressing plate body 442a and the second heater 442b are arranged similarly or identically to the first pressing plate body 441a and the first heater 441b, respectively. Therefore, a detailed description of them will be omitted. According to an alternative embodiment, the second pressing plate 442 may include a second pressing plate body 442a in which the second heater 442b is not included. In this embodiment, the second heater 442b may be separately mounted outside the second pressing plate body 442a. However, for ease of description, embodiments in which the second pressing plate 442 includes the second pressing plate body 442a and the second heater 442b will be described in detail below.

[0061] The actuator 450 can be connected to at least one of the first pressing plate 441 and the second pressing plate 442 and move said at least one of the first pressing plate 441 and the second pressing plate 442 linearly. However, for ease of description, the following will be used... Figure 2 The embodiment shown, in which the driver 450 is connected to the first pressing plate 441 and moves the first pressing plate 441 linearly, will be described in detail.

[0062] In one embodiment, the actuator 450 may have one of various configurations. In one embodiment, for example, the actuator 450 may include a cylinder connected to the first pressing plate 441. According to an alternative embodiment, the actuator 450 may include a rack gear connected to the first pressing plate 441, a pinion gear connected to the rack, and a motor connected to the pinion gear. According to another alternative embodiment, the actuator 450 may include a linear motor connected to the first pressing plate 441. In another alternative embodiment, the actuator 450 may include a ball screw connected to the first pressing plate 441 and a motor connected to the ball screw. However, the configuration of the actuator 450 is not limited thereto, and the actuator 450 may include any means or structure for linearly moving the first pressing plate 441. However, for ease of description, embodiments in which the actuator 450 includes a cylinder will be described in detail below.

[0063] In one implementation, such as Figure 3 As shown, the cooling unit 500 may include a first cooling plate 510, a second cooling plate 520, and a cooling plate driver 530. The first cooling plate 510 may include a first cooling plate body 511 and a first cooler 512, the first cooling plate body 511 contacting a sleeve 420 and a second mold 430, the first cooler 512 being mounted in the first cooling plate body 511. In this embodiment, the first cooler 512 may be arranged to have one of various configurations. In one embodiment, for example, the first cooler 512 may include a thermoelectric device. According to an alternative embodiment, the first cooler 512 may include a pipe in which a coolant, such as cooling water, flows. However, for ease of description, embodiments in which the first cooler 512 includes a pipe in which a coolant, such as cooling water, flows will be described in detail below.

[0064] In one embodiment, the second cooling plate 520 may include a second cooling plate body 521 and a second cooler 522, the second cooling plate body 521 being arranged facing the first mold 410, and the second cooler 522 being mounted in the second cooling plate body 521. In this embodiment, the second cooling plate body 521 and the second cooler 522 are the same as or similar to the first cooling plate body 511 and the first cooler 512, and any repetitive detailed descriptions of them will be omitted.

[0065] A cooling plate driver 530 may be connected to at least one of the first cooling plate 510 and the second cooling plate 520 and cause said at least one of the first cooling plate 510 and the second cooling plate 520 to move linearly. In this embodiment, the cooling plate driver 530 is the same as or similar to the driver 450, and any repetitive detailed description of them will be omitted. Hereinafter, for ease of description, a detailed description will be given of an embodiment in which the cooling plate driver 530 causes only the first cooling plate 510 to move linearly.

[0066] The unloading unit 600 can remove the cover window 10, which is conveyed by the transfer unit 200 and located on the first mold 410. In one embodiment, a robotic arm or the like may be mounted at the unloading unit 600.

[0067] The display device manufacturing apparatus 1 described above may include configurations different from those described above. In one embodiment, for example, the display device manufacturing apparatus 1 may further include a plurality of preheating units 300. In this embodiment, the display device manufacturing apparatus 1 may further include a cleaning unit (not shown) for cleaning the surface of the manufactured cover window 10. The display device manufacturing apparatus 1 may further include a drying unit (not shown) for drying the cleaning fluid by blowing hot air onto the cleaning fluid sprayed by the cleaning unit. In one embodiment, the display device manufacturing apparatus 1 may further include various means for manufacturing the display device manufacturing apparatus 1 that are different from the components described above.

[0068] In the following, one embodiment of the method for manufacturing the cover window 10 using the display device manufacturing apparatus 1 will be described in detail. In one embodiment of the method for manufacturing the cover window 10 using the display device manufacturing apparatus 1, as... Figure 1 As shown, the glass substrate M can be supplied from the outside via the loading unit 100. In this embodiment, the substrate M may have a flat plate shape.

[0069] The loading unit 100 can place or set the parent material M on the first mold 410. In one embodiment, the first mold 410 can be mounted on the conveying unit 200 such that the first mold 410 can move linearly. In one embodiment, for example, the first mold 410 can be mounted on the conveyor belt 210. According to an alternative embodiment, the first mold 410 can be mounted on a separate reciprocating shuttle (not shown) mounted on the conveyor belt 210. In this embodiment, the conveyor belt 210 and the reciprocating shuttle may have an open central portion. For ease of description, the embodiment in which the first mold 410 is directly placed on the conveyor belt 210 and moved will be described in detail below.

[0070] In one embodiment, after the base material M is placed on the first mold 410, for example, when the first mold 410, on which the base material M is placed, is moved to be positioned below the base material M, the sleeve 420 and the second mold 430 can be disposed or mounted on the first mold 410. According to an alternative embodiment, the sleeve 420 and the second mold 430 can be mounted on the first mold 410, and then the base material M can be disposed between the sleeve 420 and the second mold 430. However, for ease of description, the embodiment in which the sleeve 420 and the second mold 430 are mounted on the first mold 410 after the base material M is placed on the first mold 410 will be described in detail below.

[0071] In one embodiment, the sleeve 420 and the second mold 430 can be mounted on the first mold 410 by an external robotic arm or the like. According to an alternative embodiment, the sleeve 420 and the second mold 430 can be mounted on the first mold 410 by an operator. For ease of description, the embodiment in which the sleeve 420 and the second mold 430 are mounted on the first mold 410 by a robotic arm or the like will be described in detail below.

[0072] As the first mold 410 moves with the conveyor belt 210, the preheater 310 can be operated to heat the base material M. In one embodiment, the roller drive 230 can be repeatedly operated for a predetermined time period and then stopped for a predetermined time period.

[0073] After preheating, the base material M can be moved together with the first mold 410 to the pressing plate 440 and driver 450 of the deformation unit 400. In one embodiment, the operation of the roller driver 230 can be stopped when the first mold 410 is arranged below the sleeve 420 and the second mold 430.

[0074] The position of the first mold 410 can be adjusted to correspond to the positions of the sleeve 420 and the second mold 430. In one embodiment, the deformation unit 400 may further include a video (vision) unit 700 for determining the positions of the first mold 410, the sleeve 420, and the second mold 430. The video unit 700 can acquire images of the first mold 410, the sleeve 420, and the second mold 430 to obtain their positional information. In this embodiment, the position of the first mold 410 can be adjusted based on the positional information of the first mold 410, the sleeve 420, and the second mold 430.

[0075] In this embodiment, when the positions of the first mold 410, sleeve 420, and second mold 430 are determined to correspond to each other, the actuator 450 can be operated to move the first pressing plate 441 linearly. In this embodiment, when the second pressing plate 442 is positioned above the first mold 410, the actuator 450 can be operated to move the first pressing plate 441 linearly.

[0076] In this embodiment, when the first pressing plate 441 is moved linearly to the second pressing plate 442 as described above, the first heater 441b and the second heater 442b can be operated to heat the base material M.

[0077] The first pressing plate 441 may sequentially contact the second sub-mold 432, the first sub-mold 431, and the sleeve 420 in a predetermined order (e.g., the order of the second sub-mold 432, the first sub-mold 431, and the sleeve 420). In one embodiment, the sleeve 420 may contact the base material M and press the base material M by using the weight of the sleeve 420. In this embodiment, the first sub-mold 431 may contact the first pressing plate 441 and begin pressing a portion of the base material M. In this embodiment, the first sub-mold 431 may deform (e.g., bend) a portion of the base material M. Then, when the first pressing plate 441 contacts the second sub-mold 432, the second sub-mold 432 may contact a portion of the base material M and press the base material M.

[0078] As the first pressing plate 441 continues to move toward the sleeve 420 as described above, after a specific time has elapsed, the first pressing plate 441 can contact all of the first sub-mold 431, the second sub-mold 432, and the sleeve 420. In one embodiment, the first pressing plate 441 can press all of the first sub-mold 431, the second sub-mold 432, and the sleeve 420, such that the first sub-mold 431, the second sub-mold 432, and the sleeve 420 can press the base material M.

[0079] When the first sub-mold 431, the second sub-mold 432, and the sleeve 420 press against the base material M as described above, the first sub-mold 431, the second sub-mold 432, and the sleeve 420 can press the base material M with uniform pressure over the entire base material M. In this embodiment, it is possible to prevent the first sub-mold 431 and the second sub-mold 432 used to bend the base material M from applying excessive pressure.

[0080] If the first sub-mold 431, the second sub-mold 432, and the sleeve 420 are integrally formed as a single, inseparable component, or if the first sub-mold 431 and the second sub-mold 432 are integrally formed as a single, inseparable component and this integral component is inserted into the sleeve 420, then when the first sub-mold 431, the second sub-mold 432, and the sleeve 420 are pressed using the first pressing plate 441, the pressure applied to the sleeve 420, the pressure applied to the first sub-mold 431, and the pressure applied to the second sub-mold 432 can be different from each other. In particular, this difference in pressure can be amplified when a portion of the base material M is bent to have a large radius of curvature. In this case, the pressure difference can be based on the radius of curvature in the case of bending the base material M, and therefore the base material M can be bent differently according to the desired design. Specifically, if the first sub-mold 431 and the second sub-mold 432 are integrally formed as a single, inseparable component and the sleeve 420 is arranged separately, the pressure can vary based on the flatness between the corresponding connecting portions of the sleeve 420 to the first sub-mold 431 and the second sub-mold 432. However, in one embodiment of the display device manufacturing apparatus 1, the first sub-mold 431, the second sub-mold 432, and the sleeve 420 can be arranged independently to allow for some gaps, and thus the first sub-mold 431, the second sub-mold 432, and the sleeve 420 can be pressed evenly using the first pressing plate 441.

[0081] In this embodiment, when the positions of the first pressing plate 441 and the second pressing plate 442 are fixed after the cover window 10 is formed by pressing the base material M, the temperatures of the first heater 441b and the second heater 442b can be gradually reduced.

[0082] Next, the first mold 410, the second mold 430, and the sleeve 420 can be conveyed to the cooling unit 500 via the conveyor belt 210. At the cooling unit 500, the first cooling plate 510 and the second cooling plate 520 can contact the second mold 430, the sleeve 420, and the first mold 410, thereby cooling the cover window 10. In this embodiment, the cover window 10 can maintain its molded shape through rapid cooling.

[0083] After the above-described operations are completed, the cover window 10 can be supplied to the unloading unit 600 while it is being placed on the first mold 410. In one embodiment, the second mold 430 and the sleeve 420 can be removed from the cover window 10.

[0084] In one embodiment, as described above, the display device manufacturing apparatus 1 can sufficiently reduce defects in the cover window 10 by providing uniform pressure during the manufacturing of the cover window 10. In this embodiment, the display device manufacturing apparatus 1 can effectively prevent the formation of possible corrugated patterns at the curved portions of the cover window 10 by providing uniform pressure to the cover window 10.

[0085] Figure 4 It is shown by Figure 1 The diagram shows a cross-sectional view of a display device manufactured by the display device manufacturing apparatus shown. Figure 5 Is Figure 4 A plan view of a portion of the display device shown. Figure 6 It is along Figure 5 A cross-sectional view of line VV.

[0086] Reference Figure 4 and Figure 5 One embodiment of the display device 2 may include a cover window 10, an adhesive element 30, and a panel element 20.

[0087] The cover window 10 may be at least partially curved. In one embodiment, the cover window 10 may comprise or be formed of a transparent material, such as one of various photo-transmissive materials. In one embodiment, for example, the cover window 10 may comprise or be formed of an acrylic or plastic material. According to an alternative embodiment, the cover window 10 may comprise or be formed of a glass-based material. The cover window 10 may have a multi-layered structure comprising multiple layers formed of transparent material. For ease of description, embodiments in which the cover window 10 is formed of a glass-based material will be described in detail below.

[0088] The cover window 10 may include a flat first cover window 11, a second cover window 12 extending from the first cover window 11, and a third cover window 13 extending from the first cover window 11. In one embodiment, the second cover window 12 and the third cover window 13 may be curved portions of the cover window 10 having a predetermined radius of curvature. The radii of curvature of the second cover window 12 and the third cover window 13 may be different from each other. In one embodiment, the radius of curvature of the third cover window 13 may be greater than the radius of curvature of the second cover window 12.

[0089] Panel element 20 may include various devices. In one embodiment, for example, panel element 20 may include a display panel (not shown). According to one embodiment, panel element 20 may include a touch screen panel (TSP). According to another embodiment, panel element 20 may include a protective film attached to cover window 10. In one embodiment, the protective film can effectively prevent damage to the surface of cover window 10 (e.g., damage due to scratches or foreign matter). However, panel element 20 is not limited to those described above, and cover window 10 may include any flexible type of device that can be attached to cover window 10. However, for ease of description, embodiments in which panel element 20 includes a display panel will be described in detail below.

[0090] In one embodiment, the adhesive element 30 may be disposed on or mounted on at least one of the panel element 20 and the cover window 10. In this embodiment, the adhesive element 30 may be disposed on or mounted on the surface of the panel element 20 facing the cover window 10 or on the surface of the cover window 10 facing the panel element 20.

[0091] The adhesive element 30 may include an optical adhesive. In one embodiment, the adhesive element 30 may include an optical clearance adhesive (OCA).

[0092] Panel element 20 (display panel) may define a display area DA and a non-display area located outside the display area on substrate 21. For example, a light emitter D may be provided at the display area DA, and a power line (not shown) may be provided at the non-display area. In this embodiment, pads (pads) C may be provided at the non-display area.

[0093] The panel element 20 may include a substrate 21 and a light emitter D. In one embodiment, the organic light-emitting display panel 20 may include a thin-film encapsulation layer E disposed above the light emitter D. In one embodiment, the substrate 21 may comprise or be formed of a plastic material or a metal, such as stainless steel (SUS) or Ti. In one embodiment, the substrate 21 may comprise or be formed of polyimide (PI). For ease of description, embodiments in which the substrate 21 is formed of PI will be described in detail below.

[0094] The light emitter D can be disposed on the substrate 21. In one embodiment, a thin-film transistor (TFT) can be disposed in the light emitter D, a passivation film 27 can be disposed to cover the TFT, and an organic light-emitting device (OLED) 28 can be disposed on the passivation film 27.

[0095] A buffer layer 22 comprising organic and / or inorganic compounds is further disposed on the top surface of the substrate 21, wherein the buffer layer 22 may comprise SiOx (x≥1) and / or SiNx (x≥1) or may be formed of SiOx (x≥1) and / or SiNx (x≥1).

[0096] After the active layer 23 is disposed on the buffer layer 22 in a specific pattern, the active layer 23 is covered by the gate insulating layer 24. The active layer 23 includes a source region 23-1 and a drain region 23-3 and further includes a channel region 23-2 located between the source region 23-1 and the drain region 23-3.

[0097] The active layer 23 may be configured to comprise various materials. In one embodiment, for example, the active layer 23 may comprise an inorganic semiconductor material such as amorphous silicon or crystalline silicon. In another example, the active layer 23 may comprise an oxide semiconductor material. In yet another example, the active layer 23 may comprise an organic semiconductor material. However, for ease of description, the following description will focus on the case where the active layer 23 is formed of amorphous silicon.

[0098] The active layer 23 can be configured by forming an amorphous silicon layer on the buffer layer 22, forming a polycrystalline silicon layer by crystallizing the amorphous silicon layer, and patterning the polycrystalline silicon layer. The source region 23-1 and drain region 23-3 of the active layer 23 are doped with impurities depending on the type of TFT (such as a driving TFT (not shown) and a switching TFT (not shown)).

[0099] A gate electrode 25 corresponding to the active layer 23 and an interlayer insulating layer 26 covering the gate electrode 25 are provided on the top surface of the gate insulating layer 24.

[0100] In this embodiment, after forming a contact hole H1 through the interlayer insulating layer 26 and the gate insulating layer 24, a source electrode 27-1 and a drain electrode 27-2 are disposed on the interlayer insulating layer 26, such that the source electrode 27-1 and the drain electrode 27-2 contact the source region 23-1 and the drain region 23-3, respectively.

[0101] A passivation film 27 is disposed on the TFT as described above, and a pixel electrode 28-1 of the OLED 28 is disposed on the passivation film 27. The pixel electrode 28-1 contacts the drain electrode 27-2 of the TFT via a via H2 defined in the passivation film 27. The passivation film 27 may comprise inorganic and / or organic materials and may comprise a single layer or two or more layers, wherein the passivation film 27 may serve as a planarization layer so as to have a flat top surface regardless of whether the underlying layer is recessed, or the passivation film 27 may be recessed corresponding to the recess of the underlying layer. In this embodiment, the passivation film 27 may comprise or be formed of a transparent insulator for resonance effects.

[0102] After the pixel electrode 28-1 is disposed on the passivation film 27, a pixel defining layer 29 comprising organic and / or inorganic materials or formed of organic and / or inorganic materials is disposed to cover the pixel electrode 28-1 and the passivation film 27, wherein the pixel defining layer 29 is partially removed to expose the pixel electrode 28-1.

[0103] In this embodiment, at least an intermediate layer 28-2 and a counter electrode 28-3 are provided on the pixel electrode 28-1.

[0104] Pixel electrode 28-1 is used as an anode and counter electrode 28-3 is used as a cathode, but is not limited thereto. Alternatively, pixel electrode 28-1 may be used as a cathode and counter electrode 28-3 may be used as an anode.

[0105] The pixel electrode 28-1 and the counter electrode 28-3 are isolated from each other by an intermediate layer 28-2, wherein voltages of different polarities are applied to the intermediate layer 28-2 for light emission of the organic light-emitting layer.

[0106] Intermediate layer 28-2 may include an organic light-emitting layer. According to one embodiment, intermediate layer 28-2 may include an organic light-emitting layer and may further include at least one of the following: a hole injection layer (HIL), a hole transport layer (HTL), an electron transport layer (ETL), and an electron injection layer (EIL). However, the embodiment is not limited thereto, and intermediate layer 28-2 may include an organic light-emitting layer and may further include various other functional layers (not shown).

[0107] In one embodiment, a single unit pixel includes a plurality of sub-pixels, wherein the plurality of sub-pixels can emit light of various colors. In one embodiment, for example, the plurality of sub-pixels may include sub-pixels (not shown) for emitting red, green, and blue light, or sub-pixels (not shown) for emitting red, green, blue, and white light.

[0108] In one embodiment, the thin-film encapsulation layer E described above may include a plurality of inorganic layers or a combination of inorganic and organic layers.

[0109] The organic layer of the thin-film encapsulation layer E may comprise or be formed of a polymer, and may have a monolayer or multilayer structure. In one embodiment, the organic layer of the thin-film encapsulation layer E may comprise or be formed of any of the following: polyethylene terephthalate, polyimide, polycarbonate, epoxy resin, polyethylene, and polyacrylate. In one embodiment, for example, the organic layer may comprise or be formed of polyacrylate. In one embodiment, for example, the organic layer may comprise a polymeric monomer composition comprising diacrylate-based monomers and triacrylate-based monomers. In this embodiment, the monomer composition may further comprise photoinitiators known in the art, such as TPO, but the inventive concept is not limited thereto.

[0110] The inorganic layer of the thin-film encapsulation layer E may have a single-layer structure or a multi-layer structure comprising a metal oxide or a metal nitride. In one embodiment, the inorganic layer may comprise at least one selected from SiNx, Al2O3, SiO2, and TiO2.

[0111] The outermost layer of the thin-film encapsulation layer E exposed to the outside can be an inorganic layer used to prevent moisture from penetrating into the OLED.

[0112] In one embodiment, the thin-film encapsulation layer E may have a sandwich structure comprising two inorganic layers and an organic layer between the two inorganic layers. In an alternative embodiment, the thin-film encapsulation layer E may have a sandwich structure comprising two organic layers and an inorganic layer between the two organic layers. In another alternative embodiment, the thin-film encapsulation layer E may have a sandwich structure comprising two inorganic layers and an organic layer between the two inorganic layers, and a sandwich structure comprising two organic layers and an inorganic layer between the two organic layers.

[0113] In one embodiment, the thin-film encapsulation layer E may include a first inorganic layer, a first organic layer, and a second inorganic layer sequentially disposed on one of the top surfaces of the OLED.

[0114] In an alternative embodiment, the thin-film encapsulation layer E may include a first inorganic layer, a first organic layer, a second inorganic layer, a second organic layer, and a third inorganic layer disposed sequentially on one another from the top surface of the OLED.

[0115] In another alternative embodiment, the thin-film encapsulation layer E may include a first inorganic layer, a first organic layer, a second inorganic layer, a second organic layer, a third inorganic layer, a third organic layer, and a fourth inorganic layer disposed sequentially from the top surface of the OLED onto the other.

[0116] In one embodiment, a LiF-containing metal halide layer may be further disposed between the OLED and the first inorganic layer. The metal halide layer can effectively prevent the OLED from being damaged when the first inorganic layer is deposited by sputtering.

[0117] When viewed from a top plan view in the thickness direction of the display device 2, the first organic layer may have a smaller area than the second inorganic layer, and the second organic layer may have a smaller area than the third inorganic layer.

[0118] In one embodiment, the overlay window 10 is precisely manufactured so that the display device 2 can display images with improved quality (e.g., clearer images).

[0119] Figure 7 It is shown Figure 1 A cross-sectional view of an alternative embodiment of a variant unit of the display device manufacturing apparatus shown. Figure 8 It is shown Figure 7 The cross-sectional view of the operating state of the deformable unit shown.

[0120] Reference Figure 7 and Figure 8 Apart from the deformable unit 400-1, one embodiment of the display device manufacturing apparatus (not shown) may be substantially the same as the embodiment of the display device manufacturing apparatus described above, and any repetitive detailed descriptions of them will be omitted or simplified below.

[0121] In an alternative implementation, such as Figure 7 and Figure 8 As shown, the deformation unit 400-1 may include a first mold 410-1, a sleeve 420-1, a second mold 430-1, a pressing plate 440-1, and a driver 450-1. In this embodiment, the first mold 410-1 and the sleeve 420-1...

[0122] They are essentially the same as those described above, and any repetitive detailed descriptions of them will be omitted.

[0123] In this embodiment, the second mold 430-1 can be inserted into the sleeve 420-1. In this embodiment, an insertion hole (not shown) can be defined in the sleeve 420-1 to insert the second mold 430-1 into the insertion hole.

[0124] The second mold 430-1 may include a first sub-mold 431-1 and a second sub-mold 432-1, which are spaced apart from each other and inserted into the sleeve 420-1. In this embodiment, the first sub-mold 431-1 may include a first contact unit 431a-1 and a first pressing portion 431b-1. In this embodiment, the second sub-mold 432-1 may include a second contact unit 432a-1, a second pressing portion 432b-1, and a second protrusion 432c-1. In this embodiment, the first sub-mold 431-1 and the second sub-mold 432-1 are substantially the same as those described above, and any repetitive detailed description of them will be omitted.

[0125] Press plate 440-1 may include a first press plate 441-1 and a second press plate 442-1. In this embodiment, the first press plate 441-1 may include a first press plate body 441a-1. In an alternative embodiment, a first heater 441b-1 may be disposed spaced apart from and outside the first press plate body 441a-1. According to one embodiment, the first press plate 441-1 may include a first press plate body 441a-1 and a first heater 441b-1. In this embodiment, the first heater 441b-1 may be disposed in or fixed to the first press plate body 441a-1, and the first heater 441b-1 may move together with the first press plate body 441a-1. For ease of description, the following will describe in detail the embodiment in which the first pressing plate 441-1 includes the first pressing plate body 441a-1 and the first heater 441b-1.

[0126] The first pressing plate body 441a-1 may be configured to have a recessed surface. In one embodiment, for example, the thickness of the recessed portion of the first pressing plate body 441a-1 corresponding to the first sub-mold 431-1 and the second sub-mold 432-1 may be smaller than the thickness of the remaining portion of the first pressing plate body 441a-1. In this embodiment, the position of the recessed portion of the first pressing plate body 441a-1 may be determined based on the positions of the first sub-mold 431-1 and the second sub-mold 432-1 and the pressure applied to the first sub-mold 431-1 and the second sub-mold 432-1. The central portion of the first pressing plate body 441a-1 may protrude more than the remaining portion of the first pressing plate body 441a-1. In this embodiment, the central portion of the first pressing plate body 441a-1 may contact and press the sleeve 420-1.

[0127] According to one embodiment, the second pressing plate 442-1 may include a second pressing plate body 442a-1. According to another embodiment, the second pressing plate 442-1 may include a second pressing plate body 442a-1 and a second heater 442b-1. In this embodiment, the second pressing plate body 442a-1 and the second heater 442b-1 are substantially the same as the first pressing plate body 441a-1 and the first heater 441b-1, and any repetitive detailed description of them will be omitted. For ease of description, the following description will be directed to the case in which the second pressing plate 442-1 includes a second pressing plate body 442a-1 and a second heater 442b-1.

[0128] In one embodiment, the method for manufacturing the display device may be the same as described above. Figures 1 to 3 The methods described are essentially the same. For ease of description, the method of manufacturing the cover window 10 at deformation unit 400-1 will be briefly described below.

[0129] When the parent material M is moved through the loading unit (not shown) and heating unit (not shown) and conveyed to the deformation unit 400-1, the driver 450-1 can be operated to move the first pressing plate 441-1 to the sleeve 420-1. In this embodiment, the top of the first sub-mold 431-1 and the top of the second sub-mold 432-1 may have different heights from the sleeve 420-1. In this embodiment, the top of the second sub-mold 432-1 may be positioned higher than the top of the first sub-mold 431-1.

[0130] The first pressing plate body 441a-1 can contact the second sub-mold 432-1 and press a portion of the base material M. Here, the sleeve 420-1 can press the base material M by using the weight of the sleeve 420-1.

[0131] In this embodiment, after the first pressing plate body 441a-1 contacts the second sub-mold 432-1, the first pressing plate body 441a-1 approaches the sleeve 420-1 due to the operation of the driver 450-1. The first pressing plate body 441a-1 can sequentially contact and press the first sub-mold 431-1 and the sleeve 420-1 in a predetermined order (e.g., in the order of the first sub-mold 431-1 and the sleeve 420-1). Therefore, the first pressing plate body 441a-1 can contact and press all of the first sub-mold 431-1, the second sub-mold 432-1, and the sleeve 420-1.

[0132] When the first pressing plate body 441a-1 is pressed as described above, the first pressing plate body 441a-1 can apply uniform pressure to the first sub-mold 431-1, the second sub-mold 432-1, and the sleeve 420-1. In this embodiment, the first heater 441b-1 and the second heater 442b-1 can be operated to heat the base material M.

[0133] During the operation described above, the base material M can be deformed to have a predetermined shape for covering the window 10. After the operation described above is completed, the covering window 10 can be cooled by gradually reducing the temperature of the first pressing plate body 441a-1 and the second heater 442b-1 of the deformation unit 400-1.

[0134] In this embodiment, the cover window 10, together with the first mold 410-1, the second mold 430-1, and the sleeve 420-1, can be moved to a cooler (not shown) for rapid cooling. In this embodiment, after the cover window 10 has cooled, it can be moved to an unloading unit (not shown) and removed.

[0135] Therefore, one embodiment of the display device manufacturing apparatus can sufficiently reduce or minimize defects in the cover window 10 by providing uniform pressure during the manufacturing of the cover window 10. In this embodiment, the display device manufacturing apparatus can effectively prevent the formation of possible corrugated patterns at the curved portions of the cover window 10 by providing uniform pressure to the cover window 10.

[0136] According to the embodiments of the display device manufacturing apparatus and the method of manufacturing a display device using the display device manufacturing apparatus, a display device with improved image quality (e.g., displaying a clear image) can be efficiently manufactured.

[0137] According to the embodiments of the display device manufacturing apparatus and the method of manufacturing the display device, manufacturing defects of the cover window can be sufficiently reduced or minimized, and a precise cover window can be manufactured.

[0138] According to the embodiments of the display device manufacturing apparatus and the method for manufacturing the display device, the cover window can be manufactured online efficiently or quickly.

[0139] It should be understood that the embodiments described herein should be considered for illustrative purposes only and not for limiting purposes. The description of features or aspects within each embodiment should generally be considered applicable to other similar features or aspects in other embodiments.

[0140] Although one or more embodiments have been described with reference to the figures, those skilled in the art will understand that various changes in form and detail may be made without departing from the spirit and scope defined by the appended claims.

Claims

1. An apparatus for manufacturing a display device, the apparatus comprising: The deformation unit deforms the cover window by pressing it. The deformation unit includes: The first mold, on which the cover window is mounted; The sleeve is configured to be spaced apart from the first mold and move linearly to the first mold; A second mold, inserted into the sleeve and linearly moved to the first mold, is used to deform the portion of the cover window on the first mold; and The pressing plate presses the sleeve and the second mold into the first mold. When the pressing plate presses down on the sleeve and the second mold, the pressing plate contacts the second mold and the sleeve in sequence.

2. The apparatus for manufacturing a display device according to claim 1, wherein the insertion hole is defined in the sleeve, and the second mold is inserted into the insertion hole and moves linearly within the insertion hole.

3. The apparatus for manufacturing a display device according to claim 1, wherein the pressing plate includes a heater for heating the cover window.

4. The apparatus for manufacturing a display device according to claim 1, wherein the width of the second mold is not uniform along the length direction of the sleeve.

5. The apparatus for manufacturing a display device according to claim 1, wherein the width of the portion of the second mold near the sleeve is greater than the width of the portion of the second mold near the first mold.

6. The apparatus for manufacturing a display device according to claim 1, wherein... The second mold comprises a plurality of sub-molds spaced apart from each other, and The plurality of sub-molds are configured to move linearly to contact the portion of the cover window to be deformed.

7. The apparatus for manufacturing a display device according to claim 1, wherein the step is defined between the portion of the pressing plate that contacts the second mold and the portion of the pressing plate that contacts the sleeve.

8. The apparatus for manufacturing a display device according to claim 1, further comprising: A cooler for cooling the cover window that is being transported from the deforming unit.

Images