Curved display device and method for manufacturing the same

Abstract

A curved display device is provided, comprising one or more bending portions, wherein the curved display device is bent at the bending portions. At least one or more bending portions of the curved display device include a stacked structure, wherein the stacked structure includes: a support layer; a display panel on the support layer; and N pressure-sensitive adhesive layers and M flexible base layers between the support layer and the display panel, wherein N is an integer greater than or equal to 3, and M is an integer greater than or equal to 2. The first layer of the N pressure-sensitive adhesive layers bonds the support layer and the first layer of the M flexible base layers together. The last layer of the N pressure-sensitive adhesive layers bonds the display panel and the last layer of the M flexible base layers together.

Description

Technical Field

[0001] The present invention relates to display technology, and more particularly, to a curved display device and a method for manufacturing the curved display device. Background Art

[0002] Traditional display devices are typically flat panel displays. In recent years, due to design or other reasons, display devices with curved display surfaces have been developed. Curved display devices are now used in computer monitors, televisions, personal portable devices, and displays installed in vehicles. Summary of the Invention

[0003] In one aspect, this disclosure provides a curved display device including one or more bending portions, the curved display device being bent at the bending portions; wherein at least one or more bending portions of the curved display device include a stacked structure, the stacked structure including: a support layer; a display panel on the support layer; and N pressure-sensitive adhesive layers and M flexible base layers between the support layer and the display panel, where N is an integer greater than or equal to 3 and M is an integer greater than or equal to 2; wherein the N pressure-sensitive adhesive layers and the M flexible base layers are arranged alternately; the N pressure-sensitive adhesive layers are arranged in a specific order. A layer bonds the support layer and the first layer of the M flexible substrates together; the last layer of the N pressure-sensitive adhesive layers bonds the display panel and the last layer of the M flexible substrates together; the thickness of each pressure-sensitive adhesive layer in the N pressure-sensitive adhesive layers is in the range of 30 μm to 55 μm; the thickness of each flexible substrate in the M flexible substrates is in the range of 20 μm to 40 μm; and the ratio of the thickness of each pressure-sensitive adhesive layer in the N pressure-sensitive adhesive layers to the thickness of each flexible substrate in the M flexible substrates is in the range of 0.75 to 2.75.

[0004] Optionally, the ratio of the thickness of each pressure-sensitive adhesive layer in the N pressure-sensitive adhesive layers to the thickness of each flexible substrate in the M flexible substrates is in the range of 1.5 to 1.375.

[0005] Optionally, the curved display device further includes a substantially flat portion connected to the one or more bends; wherein the stacking structure is a structure extending over the entire substantially flat portion and the one or more bends; the stacking structure bends in the one or more bends; and the N pressure-sensitive adhesive layers and the M flexible base layers extend over the entire substantially flat portion and the one or more bends.

[0006] Optionally, the support layer is a metal support layer.

[0007] Optionally, the stacked structure further includes: a polarizer located on a side of the display panel away from the support layer; an optically transparent adhesive layer located on a side of the polarizer away from the display panel; and a cover located on a side of the optically transparent adhesive layer away from the polarizer.

[0008] Optionally, each of the N pressure-sensitive adhesive layers includes an acrylic-based adhesive material; and each of the M flexible base layers includes an organic material.

[0009] Optionally, the n-th pressure-sensitive adhesive layer among the N pressure-sensitive adhesive layers is adhered to two adjacent flexible base layers among the M flexible base layers, where 1 < n < N; and the m-th flexible base layer among the M flexible base layers is adhered to two adjacent pressure-sensitive adhesive layers among the N pressure-sensitive adhesive layers, where 1 ≤ m ≤ M.

[0010] In another aspect, the present disclosure provides a method of manufacturing a curved display device, including: providing a display panel; providing a support layer; using N pressure-sensitive adhesive layers and M flexible base layers to bond the display panel and the support layer, where N is an integer greater than or equal to 3 and M is an integer greater than or equal to 2; and bending a component including the display panel, the support layer, the N pressure-sensitive adhesive layers, and the M flexible base layers to form one or more bending portions in the component; wherein bonding the display panel and the support layer includes: bonding the first layer among the N pressure-sensitive adhesive layers to the surface of the support layer to bond the support layer and the first layer among the M flexible base layers together; and bonding the display panel to the last layer among the N pressure-sensitive adhesive layers to bond the display panel and the last layer among the M flexible base layers together; wherein at least the one or more bending portions are formed to include a stacked structure that sequentially includes the support layer, the N pressure-sensitive adhesive layers, the M flexible base layers, and the display panel; the N pressure-sensitive adhesive layers and the M flexible base layers are alternately arranged; the thickness of each of the N pressure-sensitive adhesive layers is in the range of 30 μm to 55 μm; the thickness of each of the M flexible base layers is in the range of 20 μm to 40 μm; and the ratio of the thickness of each of the N pressure-sensitive adhesive layers to the thickness of each of the M flexible base layers is in the range of 0.75 to 2.75.

[0011] Optionally, the ratio of the thickness of each of the N pressure-sensitive adhesive layers to the thickness of each of the M flexible base layers is in the range of 1.5 to 1.375.

[0012] Optionally, bending the component further forms a substantially flat portion connected to the one or more bends; wherein the stacked structure is a structure extending over the entire substantially flat portion and the one or more bends; the stacked structure bends in the one or more bends; and the N pressure-sensitive adhesive layers and the M flexible base layers extend over the entire substantially flat portion and the one or more bends.

[0013] Optionally, the method further includes: forming a polarizer on the side of the display panel away from the support layer; forming an optically transparent adhesive layer on the side of the polarizer away from the display panel; and forming a cover on the side of the optically transparent adhesive layer away from the polarizer.

[0014] Optionally, the method further includes forming an adhesive module by forming a stacked structure comprising the N pressure-sensitive adhesive layers and the M flexible base layers, a first protective film, and a second protective film stacked alternately together.

[0015] Optionally, the method further includes forming an adhesive support module; wherein forming the adhesive support module includes: removing the first protective film from the adhesive module; and bonding the support layer to the first layer of the N pressure-sensitive adhesive layers, wherein the first layer of the N pressure-sensitive adhesive layers is bonded to the surface of the support layer.

[0016] Optionally, the method further includes: removing the second protective film from the adhesive module; and adhering the display panel to the last layer of the N pressure-sensitive adhesive layers. Attached Figure Description

[0017] The following drawings are examples for illustration purposes only and are not intended to limit the scope of the invention, in accordance with various disclosed embodiments.

[0018] Figure 1A is a perspective view of a curved display device according to some embodiments of the present disclosure.

[0019] Figure 1B It is along Figure 1A A cross-sectional view of the AA' line in the curved display device.

[0020] Figure 2A yes Figure 1B A magnified cross-sectional view of the first magnified region in the image.

[0021] Figure 2B yes Figure 1B An enlarged cross-sectional view of the second enlarged area in FIG.

[0022] Figure 2CIt is a stacked structure in a curved display device according to some embodiments of the present disclosure.

[0023] Figure 3A This is a schematic diagram illustrating an adhesive module according to some embodiments of the present disclosure.

[0024] Figure 3B This is a schematic diagram illustrating an adhesive module according to some embodiments of the present disclosure.

[0025] Figure 3C This is a schematic diagram illustrating an adhesive support module according to some embodiments of the present disclosure.

[0026] Figures 4A to 4C A method for manufacturing a curved display device according to some embodiments of the present disclosure is shown. Detailed Implementation

[0027] The present disclosure will now be described in more detail with reference to the following examples. It should be noted that the following description of some of the embodiments presented herein is for illustration and description purposes only. It is not intended to be exhaustive or limited to the precise forms disclosed.

[0028] This disclosure provides, in particular, a curved display device and a method for manufacturing a curved display device, which substantially avoids one or more problems caused by the limitations and disadvantages of the prior art. In one aspect, this disclosure provides a curved display device. In some embodiments, the curved display device includes one or more bends at which it bends. In some embodiments, at least one or more bends of the curved display device include a stacked structure comprising: a support layer; a display panel on the support layer; and N pressure-sensitive adhesive layers and M flexible base layers between the support layer and the display panel, where N is an integer greater than or equal to 3 and M is an integer greater than or equal to 2. Optionally, the N pressure-sensitive adhesive layers and the M flexible base layers are arranged alternately. Optionally, a first layer of the N pressure-sensitive adhesive layers bonds the support layer and a first layer of the M flexible base layers together. Optionally, a last layer of the N pressure-sensitive adhesive layers bonds the display panel and the last layer of the M flexible base layers together. Optionally, the thickness of each of the N pressure-sensitive adhesive layers is in the range of 30 μm to 55 μm. Optionally, the thickness of each of the M flexible base layers is in the range of 20 μm to 40 μm. Optionally, the ratio of the thickness of each of the N pressure-sensitive adhesive layers to the thickness of each of the M flexible base layers is in the range of 0.75 to 2.75.

[0029] Figure 1AThis is a perspective view of a curved display device according to some embodiments of the present disclosure. (Refer to...) Figure 1A In some embodiments, the curved display device includes one or more bends BP in which the curved display device is bent. In one example, the curved display device also includes a substantially flat portion SFP connected to one or more bends BP.

[0030] Figure 1B It is along Figure 1A A cross-sectional view of the AA' line in the curved display device. Figure 2A yes Figure 1B A magnified cross-sectional view of the first magnified region. (Refer to...) Figure 1B and Figure 2A In some embodiments, the substantially flat portion SFP comprises a stacked structure. In some embodiments, the stacked structure comprises a support layer SUS, a display panel DP on the support layer SUS, and N pressure-sensitive adhesive layers (PSA1, ..., PSAN) and M flexible base layers (BL1, ..., BLM) between the support layer and the display panel, where N is an integer greater than or equal to 3, and M is an integer greater than or equal to 2. Figure 1B and Figure 2A As shown, N pressure-sensitive adhesive layers and M flexible base layers are arranged alternately. The first layer (PSA1) of the N pressure-sensitive adhesive layers bonds the support layer SUS to the first layer (BL1) of the M flexible base layers. The last layer (PSAN) of the N pressure-sensitive adhesive layers bonds the display panel DP to the last layer of the M flexible base layers. The stacked structure in the substantially flat portion SFP is substantially flat.

[0031] Figure 2B yes Figure 1B The enlarged cross-sectional view of the second enlarged region. (Refer to...) Figure 2B and Figure 2A In some embodiments, each of the one or more bending portions BP includes a stacked structure. In some embodiments, the stacked structure includes a support layer SUS, a display panel DP on the support layer SUS, and N pressure-sensitive adhesive layers (PSA1, ..., PSAN) and M flexible base layers (BL1, ..., BLM) between the support layer and the display panel, where N is an integer greater than or equal to 3, and M is an integer greater than or equal to 2. Figure 1B and Figure 2A As shown, N pressure-sensitive adhesive layers and M flexible substrates are arranged alternately. The first layer (PSA1) of the N pressure-sensitive adhesive layers bonds the support layer SUS and the first layer (BL1) of the M flexible substrates together. The last layer (PSAN) of the N pressure-sensitive adhesive layers bonds the display panel DP and the last layer of the M flexible substrates together. The stacked structure is bent in one or more bends BP.

[0032] like Figure 1B , Figure 2A and Figure 2B As shown, in some embodiments, the stacked structure is a structure extending over the entire substantially flat portion SFP and one or more bent portions BP. Figure 1B , Figure 2A and Figure 2B As shown, N pressure-sensitive adhesive layers and M flexible base layers extend over the entire substantially flat portion SFP and one or more bent portions BP. Optionally, the support layer SUS extends over the entire substantially flat portion SFP and one or more bent portions BP. Optionally, the display panel extends over the entire substantially flat portion SFP and one or more bent portions BP.

[0033] Figure 2C is a stacked structure in a curved display device according to some embodiments of the present disclosure. Figure 2C , in some embodiments, N=3, and M=2. The stacked structure includes a supporting layer SUS, a first pressure-sensitive adhesive layer PSA1 on the supporting layer SUS, a first flexible base layer BL1 located on a side of the first pressure-sensitive adhesive layer PSA1 away from the supporting layer SUS, a second pressure-sensitive adhesive layer PSA2 located on a side of the first flexible base layer BL1 away from the first pressure-sensitive adhesive layer PSA1, a second flexible base layer BL2 located on a side of the second pressure-sensitive adhesive layer PSA2 away from the first flexible base layer BL1, a third pressure-sensitive adhesive layer PSA3 located on a side of the second flexible base layer BL2 away from the second pressure-sensitive adhesive layer PSA2, and a display panel DP located on a side of the third pressure-sensitive adhesive layer PSA3 away from the second flexible base layer BL2.

[0034] In some embodiments, the nth pressure-sensitive adhesive layer among the N pressure-sensitive adhesive layers is bonded to two adjacent flexible base layers among the M flexible base layers, wherein 1 <n<N。

[0035] In some embodiments, an m-th flexible base layer among the M flexible base layers is bonded to two adjacent pressure-sensitive adhesive layers among the N pressure-sensitive adhesive layers, where 1≤m≤M.

[0036] The inventors of this disclosure have surprisingly and unexpectedly discovered that the stacked structure of the present invention, having N pressure-sensitive adhesive layers and M flexible base layers alternately arranged between the display panel DP and the support layer SUS, achieves excellent adhesive properties in bonding the display panel DP and the support layer SUS together. Compared to single-layer adhesives that are typically prone to cracking after 24 hours under bending strain and stress when the display panel DP and the support layer SUS are bent, the structure of the present invention is highly resistant to cracking or other damage when the display panel DP and the support layer SUS are bent. In particular, when the thicknesses of the pressure-sensitive adhesive layers and the flexible base layers are within certain selected ranges, the stacked structure remains substantially crack-free for months or longer.

[0037] In some embodiments, the thickness of each of the N pressure-sensitive adhesive layers is in the range of 30 μm to 55 μm; the thickness of each of the M flexible substrates is in the range of 20 μm to 40 μm; and the ratio of the thickness of each of the N pressure-sensitive adhesive layers to the thickness of each of the M flexible substrates is in the range of 0.75 to 2.75. Optionally, the thickness of each of the N pressure-sensitive adhesive layers is in the range of 30 μm to 35 μm, 35 μm to 40 μm, 40 μm to 45 μm, 45 μm to 50 μm, or 50 μm to 55 μm. Optionally, the thickness of each of the M flexible substrates is in the range of 20 μm to 25 μm, 25 μm to 30 μm, 30 μm to 35 μm, or 35 μm to 40 μm. Optionally, the ratio of the thickness of each of the N pressure-sensitive adhesive layers to the thickness of each of the M flexible substrates is within the range of 0.75 to 1.0, 1.0 to 1.25, 1.25 to 1.50, 1.50 to 1.75, 1.75 to 2.0, 2.0 to 2.25, 2.25 to 2.5, or 2.5 to 2.75. The inventors of this disclosure have discovered that when the thicknesses of the pressure-sensitive adhesive layers and the flexible substrates are within these selected ranges, the curved display device exhibits unexpected resistance to cracking and other damage associated with bending strain and stress.

[0038] Various suitable materials and manufacturing methods can be used to manufacture pressure-sensitive adhesive layers. For example, pressure-sensitive adhesive materials can be used to form pressure-sensitive adhesive layers. Examples of suitable pressure-sensitive adhesive materials include, but are not limited to, acrylic-based adhesive materials, such as homopolymers and copolymers of acrylic acid, methacrylic acid, isooctyl acrylate, acrylamide, methacrylamide, acrylonitrile, methacrylonitrile, methyl isoamyl acrylate, octyl 2-acrylate, and butyl acrylate. Optionally, the pressure-sensitive adhesive layer is an optically transparent adhesive layer. Optionally, the pressure-sensitive adhesive layer is a thermosensitive adhesive layer.

[0039] Various suitable materials and manufacturing methods can be used to manufacture flexible substrates. Examples of suitable flexible materials include, but are not limited to, various polymers such as polyimide, polycarbonate, polyethersulfone, polyethylene terephthalate, polyethylene naphthalate, polyarylate, and fiber-reinforced plastics. Optionally, flexible substrates include foam materials.

[0040] Various suitable materials and manufacturing methods can be used to manufacture the support layer SUS. Optionally, the support layer SUS includes an organic material layer. In one example, an organic polymer material can be used to form the organic material layer (e.g., a foam layer). Examples of suitable organic polymer materials include, but are not limited to, polyethylene terephthalate. Optionally, the support layer SUS includes a metallic support layer. Various suitable materials and manufacturing methods can be used to manufacture the metallic support layer. For example, metallic materials can be used to form the metallic support layer. Examples of suitable metallic materials include, but are not limited to, aluminum and copper, as well as various suitable alloys or laminates.

[0041] Reference Figure 1B In some embodiments, the curved display device further includes a polarizer PL located on the side of the display panel DP away from the support layer SUS; an optically clear adhesive layer OCA located on the side of the polarizer PL away from the display panel DP; and a cover CG located on the side of the optically clear adhesive layer OCA away from the polarizer PL. Optionally, the cover CG is a flexible cover glass. Optionally, the cover CG is a flexible cover film.

[0042] Various suitable materials and manufacturing methods can be used to manufacture optically clear adhesive layers (OCAs). Examples of suitable optically clear adhesive materials include, but are not limited to, polyacrylic acid, such as polymethyl methacrylate (PMMA); cyclic olefin copolymers; polycarbonate; epoxy resins; silicone-based optically clear adhesive materials; or combinations thereof.

[0043] Various suitable materials and manufacturing methods can be used to manufacture the cover CG. Examples of suitable materials for manufacturing the cover CG include, but are not limited to, polyamines, such as colorless polyamines, thin glass, ultrathin glass, polyethylene terephthalate, polyacrylate, polymethyl methacrylate, polycarbonate, polyethylene naphthalate, polyvinylidene chloride, polyvinylidene fluoride, polystyrene, ethylene vinyl alcohol copolymers, and / or combinations thereof. Optionally, the cover CG has a double-layer structure comprising a first sub-layer, a second sub-layer, and an adhesive sub-layer bonding the first sub-layer and the second sub-layer together. Optionally, the first sub-layer and the second sub-layer are made of colorless polyamine, and the adhesive sub-layer is an optically transparent adhesive sub-layer. Optionally, the cover CG further includes a hard coating sub-layer. Optionally, the cover CG also includes a protective film.

[0044] Optionally, the thickness of the support layer SUS is in the range of 50 μm to 200 μm, for example, 50 μm to 60 μm, 60 μm to 70 μm, 70 μm to 80 μm, 80 μm to 90 μm, 90 μm to 100 μm, 100 μm to 110 μm, 110 μm to 120 μm, 120 μm to 130 μm, 130 μm to 140 μm, 140 μm to 150 μm, 150 μm to 160 μm, 160 μm to 170 μm, 170 μm to 180 μm, 180 μm to 190 μm, or 190 μm to 200 μm. Optionally, the thickness of the support layer SUS is 100 μm.

[0045] Optionally, the total thickness of the N pressure-sensitive adhesive layers and the M flexible substrates is in the range of 60 μm to 260 μm, for example, 60 μm to 70 μm, 70 μm to 80 μm, 80 μm to 90 μm, 90 μm to 100 μm, 100 μm to 110 μm, 110 μm to 120 μm, 120 μm to 130 μm, 130 μm to 140 μm, 140 μm The thickness can be 150 μm to 160 μm, 160 μm to 170 μm, 170 μm to 180 μm, 180 μm to 190 μm, 190 μm to 200 μm, 200 μm to 210 μm, 210 μm to 220 μm, 220 μm to 230 μm, 230 μm to 240 μm, 240 μm to 250 μm, or 250 μm to 260 μm. Optionally, the total thickness of the N pressure-sensitive adhesive layers and the M flexible substrates is 130 μm.

[0046] Optionally, the thickness of the display panel DP is in the range of 20μm to 80μm, for example, 20μm to 30μm, 30μm to 40μm, 40μm to 50μm, 50μm to 60μm, 60μm to 70μm, or 70μm to 80μm. Optionally, the thickness of the display panel DP is 38μm.

[0047] Optionally, the thickness of the polarizer PL is in the range of 35 μm to 130 μm, for example, 35 μm to 40 μm, 40 μm to 50 μm, 50 μm to 60 μm, 60 μm to 70 μm, 70 μm to 80 μm, 90 μm to 100 μm, 100 μm to 110 μm, 110 μm to 120 μm, or 120 μm to 130 μm. Optionally, the thickness of the polarizer PL is 67 μm.

[0048] Optionally, the thickness of the optically clear adhesive layer (OCA) is in the range of 25 μm to 100 μm, for example, 25 μm to 30 μm, 30 μm to 40 μm, 40 μm to 50 μm, 50 μm to 60 μm, 60 μm to 70 μm, 70 μm to 80 μm, 80 μm to 90 μm, or 90 μm to 100 μm. Optionally, the thickness of the optically clear adhesive layer (OCA) is 50 μm.

[0049] Optionally, the thickness of the cap CG is in the range of 45 μm to 180 μm, for example, 45 μm to 50 μm, 50 μm to 60 μm, 60 μm to 70 μm, 70 μm to 80 μm, 90 μm to 100 μm, 100 μm to 110 μm, 110 μm to 120 μm, 120 μm to 130 μm, 130 μm to 140 μm, 140 μm to 150 μm, 150 μm to 160 μm, 160 μm to 170 μm, or 170 μm to 180 μm. Optionally, the thickness of the cap CG is 90 μm.

[0050] In another aspect, this disclosure provides a method for manufacturing a curved display device. In some embodiments, the method includes: setting a display panel; setting a support layer; bonding the display panel and the support layer using N pressure-sensitive adhesive layers and M flexible base layers, where N is an integer greater than or equal to 3 and M is an integer greater than or equal to 2; and bending an assembly including the display panel, the support layer, the N pressure-sensitive adhesive layers, and the M flexible base layers to form one or more bends in the assembly. Optionally, bonding the display panel and the support layer includes: bonding a first layer of the N pressure-sensitive adhesive layers to the surface of the support layer, thereby bonding the support layer and the first layer of the M flexible base layers together; and bonding the display panel to the last layer of the N pressure-sensitive adhesive layers, thereby bonding the display panel and the last layer of the M flexible base layers together. Optionally, at least the one or more bends are formed to include a stacked structure, the stacked structure sequentially including the support layer, the N pressure-sensitive adhesive layers, the M flexible base layers, and the display panel. Optionally, the N pressure-sensitive adhesive layers and the M flexible substrates are arranged alternately. Optionally, the thickness of each of the N pressure-sensitive adhesive layers is in the range of 30 μm to 55 μm. Optionally, the thickness of each of the M flexible substrates is in the range of 20 μm to 40 μm. Optionally, the ratio of the thickness of each of the N pressure-sensitive adhesive layers to the thickness of each of the M flexible substrates is in the range of 0.75 to 2.75. Optionally, the ratio of the thickness of each of the N pressure-sensitive adhesive layers to the thickness of each of the M flexible substrates is in the range of 1.5 to 1.375.

[0051] In some embodiments, bending the component further forms a substantially flat portion connected to the one or more bends. Optionally, the stacked structure is a structure that extends over the entire substantially flat portion and the one or more bends. Optionally, the stacked structure is bent within the one or more bends. Optionally, the N pressure-sensitive adhesive layers and the M flexible base layers extend over the entire substantially flat portion and the one or more bends.

[0052] In some embodiments, the method further includes: forming a polarizer on the side of the display panel away from the support layer; forming an optically transparent adhesive layer on the side of the polarizer away from the display panel; and forming a cover on the side of the optically transparent adhesive layer away from the polarizer.

[0053] In some embodiments, the method further includes forming an adhesive module. Figure 3A FIG is a diagram illustrating an adhesive module according to some embodiments of the present disclosure. Figure 3A In some embodiments, forming the adhesive module includes forming a stacked structure comprising N pressure-sensitive adhesive layers (PSA1, ..., PSAN) and M flexible substrates (BL1, ..., BLM), a first protective film PF1, and a second protective film PF2, alternately stacked together. The nth pressure-sensitive adhesive layer of the N pressure-sensitive adhesive layers is bonded to two adjacent flexible substrates of the M flexible substrates, where 1 < n < N. The mth flexible substrate of the M flexible substrates is bonded to two adjacent pressure-sensitive adhesive layers of the N pressure-sensitive adhesive layers, where 1 ≤ m ≤ M. The first layer of the N pressure-sensitive adhesive layers bonds the first protective film PF1 and the first layer of the M flexible substrates together. The last layer of the N pressure-sensitive adhesive layers bonds the second protective film PF2 and the last layer of the M flexible substrates together. Figure 3B This is a diagram illustrating an adhesive module according to some embodiments of the present disclosure. Figure 3B An example in which N=3 and M=2 is shown.

[0054] Various suitable materials and manufacturing methods can be used to manufacture protective films. Examples of suitable protective film materials include, but are not limited to, various polymers such as polyethylene terephthalate, plastics, and fibrous materials.

[0055] Various suitable methods (e.g., coating and roll-to-roll processing) can be used to assemble the layers of the adhesive module together. In a roll-to-roll process, a first flexible material (e.g., a pressure-sensitive adhesive layer or a flexible base layer) is continuously dispensed from a first roll, optionally processed, and rewound onto a second roll, where the first flexible material is bonded or laminated to a second flexible material (e.g., another flexible base layer or another pressure-sensitive adhesive layer).

[0056] In the adhesive module of the present invention, each of the N pressure-sensitive adhesive layers has a thickness ranging from 30 μm to 55 μm; each of the M flexible substrates has a thickness ranging from 20 μm to 40 μm; and the thickness ratio of a corresponding layer of the N pressure-sensitive adhesive layers to a corresponding layer of the M flexible substrates is in the range of 0.75 to 2.75. Optionally, each of the N pressure-sensitive adhesive layers has a thickness ranging from 30 μm to 35 μm, 35 μm to 40 μm, 40 μm to 45 μm, 45 μm to 50 μm, or 50 μm to 55 μm. Optionally, the thickness of each of the M flexible substrates is in the range of 20 μm to 25 μm, 25 μm to 30 μm, 30 μm to 35 μm, or 35 μm to 40 μm. Optionally, the ratio of the thickness of a corresponding one of the N pressure-sensitive adhesive layers to the thickness of a corresponding one of the M flexible substrates is in the range of 0.75 to 1.0, 1.0 to 1.25, 1.25 to 1.50, 1.50 to 1.75, 1.75 to 2.0, 2.0 to 2.25, 2.25 to 2.5, or 2.5 to 2.75. The inventors of this disclosure have discovered that when the thicknesses of the pressure-sensitive adhesive layers and the flexible substrates are within these selected ranges, the adhesive module of the present invention exhibits unexpected resistance to cracks and other damage associated with bending strain and stress.

[0057] In some embodiments, the method further includes forming an adhesive support module for bending the display panel. Figure 3C This is a schematic diagram illustrating an adhesive support module according to some embodiments of the present disclosure. Reference Figure 3C In some embodiments, the adhesive support module includes a stacked structure comprising a support layer SUS, N pressure-sensitive adhesive layers (PSA1, ..., PSAN) alternately stacked together and bonded to the surface of the support layer SUS, M flexible base layers (BL1, ..., BLM), and a second protective film PF2. A first layer of the N pressure-sensitive adhesive layers bonds the support layer SUS to a first layer of the M flexible base layers. A last layer of the N pressure-sensitive adhesive layers bonds the second protective film PF2 to a last layer of the M flexible base layers.

[0058] Figures 4A to 4CA method for manufacturing a curved display device according to some embodiments of the present disclosure is illustrated. (Refer to...) Figure 4A In some embodiments, the method includes providing a removed protective film (e.g., Figure 3C The adhesive support module ASM of the second protective film PF2 in the display panel DP, the polarizer PL, the optically transparent adhesive layer OCA and the cover CG are provided. The adhesive support module ASM and the display module are aligned with each other. Figure 4B The display module is bonded to the adhesive support module ASM, and the surface of the display panel is bonded to the last pressure-sensitive adhesive layer in the adhesive support module ASM to form the display device. (See reference...) Figure 4C The display device is bent to form one or more bent portions BP and a substantially flat portion SFP, thereby forming a curved display device. The inventors of the present disclosure have discovered that the curved display device manufactured by the method of the present invention is unexpectedly resistant to cracking and other damage associated with bending strain and stress, particularly when the thickness of the pressure-sensitive adhesive layer and the flexible base layer are within certain selected ranges.

[0059] Examples of suitable curved display devices include, but are not limited to, electronic paper, mobile phones, tablet computers, televisions, monitors, laptop computers, digital photo albums, GPS, etc. Optionally, the curved display device further includes one or more integrated circuits connected to the display panel. Optionally, the display panel is an organic light-emitting diode (OLED) display panel. Optionally, the display panel is a miniature OLED display panel.

[0060] The foregoing description of the embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms or exemplary embodiments disclosed. Therefore, the foregoing description should be considered illustrative rather than restrictive. Obviously, many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described to explain the principles of the invention and its best mode practical application, thereby enabling those skilled in the art to understand the various embodiments of the invention and various modifications as are suited to the particular use or implementation contemplated. The scope of the present invention is intended to be defined by the appended claims and their equivalents, in which all terms are to be used in their broadest reasonable sense unless otherwise indicated. Therefore, the terms "the invention," "the present invention," etc. do not necessarily limit the scope of the claims to specific embodiments, and reference to exemplary embodiments of the present invention is not intended to limit the invention, and no such limitation should be inferred. The present invention is limited solely by the spirit and scope of the appended claims. Furthermore, the claims may use the terms "first," "second," etc., followed by a noun or element. These terms should be understood as nomenclature and should not be construed as limiting the number of elements to which they refer unless a specific number is provided. Any advantages and benefits described may not apply to all embodiments of the invention. It should be understood that changes to the described embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the appended claims. Furthermore, the elements and components in this disclosure are not intended for public distribution, whether or not they are expressly recited in the appended claims.

Claims

1. A curved display device, which includes one or more bending portions, and the curved display device is bent at the bending portions; in, At least the one or more bending portions of the curved display device include a stacked structure, and the stacked structure includes: A support layer; A display panel on the support layer; and N pressure-sensitive adhesive layers and M flexible base layers between the support layer and the display panel, where N is an integer greater than or equal to 3, and M is an integer greater than or equal to 2; Wherein, the N pressure-sensitive adhesive layers and the M flexible base layers are alternately arranged; The first layer of the N pressure-sensitive adhesive layers bonds the support layer and the first layer of the M flexible base layers together; The last layer of the N pressure-sensitive adhesive layers bonds the display panel and the last layer of the M flexible base layers together; The thickness of each of the N pressure-sensitive adhesive layers is in the range of 30 μm to 35 μm; The thickness of each of the M flexible base layers is in the range of 20 μm to 30 μm; and The ratio of the thickness of each of the N pressure-sensitive adhesive layers to the thickness of each of the M flexible base layers is in the range of 1.5 to 1.75; Each of the N pressure-sensitive adhesive layers includes an acrylic-based adhesive material; and Each of the M flexible base layers includes an organic material.

2. The curved display device according to claim 1, further including a substantially flat portion connected to the one or more bending portions; in, The stacked structure is a structure extending over the entire substantially flat portion and the one or more bending portions; The stacked structure is bent in the one or more bending portions; And The N pressure-sensitive adhesive layers and the M flexible base layers extend over the entire substantially flat portion and the one or more bending portions.

3. The curved display device according to any one of claims 1 to 2, wherein: The support layer is a metal support layer.

4. The curved display device according to any one of claims 1 to 2, wherein: The stacked structure further includes: A polarizer, which is located on the side of the display panel away from the support layer; An optically transparent adhesive layer, which is located on the side of the polarizer away from the display panel; and A cover, which is located on the side of the optically transparent adhesive layer away from the polarizer.

5. The curved display device according to any one of claims 1 to 2, wherein: The nth pressure-sensitive adhesive layer of the N pressure-sensitive adhesive layers is bonded to two adjacent flexible base layers of the M flexible base layers, where 1 < n < N; and The mth flexible base layer of the M flexible base layers is bonded to two adjacent pressure-sensitive adhesive layers of the N pressure-sensitive adhesive layers, where 1 ≤ m ≤ M.

6. A method for manufacturing a curved display device, including: Setting a display panel; Setting a support layer; Using N pressure-sensitive adhesive layers and M flexible base layers to bond the display panel and the support layer, where N is an integer greater than or equal to 3, and M is an integer greater than or equal to 2; And Bending a component including the display panel, the support layer, the N pressure-sensitive adhesive layers and the M flexible base layers, so as to form one or more bending portions in the component; Wherein, bonding the display panel and the support layer comprises: Adhere a first layer of the N pressure-sensitive adhesive layers to a surface of the support layer, thereby adhering the support layer and the first layer of the M flexible base layers together; and Adhere the display panel to the last layer of the N pressure-sensitive adhesive layers, thereby adhering the display panel and the last layer of the M flexible base layers together; Wherein, at least the one or more bending portions are formed to include a stacked structure, and the stacked structure sequentially includes the support layer, the N pressure-sensitive adhesive layers, the M flexible base layers, and the display panel; The N pressure-sensitive adhesive layers and the M flexible base layers are arranged alternately; The thickness of each of the N pressure-sensitive adhesive layers is in the range of 30 μm to 35 μm; The thickness of each of the M flexible base layers is in the range of 20 μm to 30 μm; and A ratio of a thickness of each of the N pressure-sensitive adhesive layers to a thickness of each of the M flexible base layers is in a range of 1.5 to 1.75; Each of the N pressure-sensitive adhesive layers comprises an acrylic-based adhesive material; and Each of the M flexible base layers includes an organic material.

7. The method according to claim 6, wherein: A ratio of a thickness of each of the N pressure-sensitive adhesive layers to a thickness of each of the M flexible base layers is in a range of 1.5 to 1.

375.

8. The method according to claim 6, wherein: bending the assembly to further form a substantially flat portion connected to the one or more bends; wherein the stacked structure is a structure extending over the entire substantially flat portion and the one or more bent portions; The stacked structure is bent in the one or more bending portions; and The N pressure-sensitive adhesive layers and the M flexible base layers extend over the entirety of the substantially planar portion and the one or more bends.

9. The method according to any one of claims 6 to 8, further comprising: forming a polarizer on a side of the display panel away from the supporting layer; forming an optically transparent adhesive layer on a side of the polarizer away from the display panel; as well as A cover is formed on a side of the optically clear adhesive layer away from the polarizer.

10. The method according to any one of claims 6 to 8, further comprising forming an adhesive module by forming a stack structure, the stack structure comprising the N pressure-sensitive adhesive layers and the M flexible base layers, the first protective film, and the second protective film alternately stacked together.

11. The method of claim 10, further comprising forming an adhesive support module; in, Forming the adhesive support module includes: removing the first protective film from the adhesive module; and The support layer is bonded to the first layer of the N pressure-sensitive adhesive layers, and the first layer of the N pressure-sensitive adhesive layers is bonded to a surface of the support layer.

12. The method according to claim 11, further comprising: removing the second protective film from the adhesive module; as well as The display panel is bonded to the last of the N pressure-sensitive adhesive layers.

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