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

Abstract

A cover window, a method for manufacturing a cover window, and a display device having a cover window are disclosed. The cover window may include a polymer film, a printed layer, and a hard coating layer, with the printed layer disposed below the polymer film. The hard coating layer may include a first portion disposed on the top surface of the polymer film and overlapping the polymer film, a second portion disposed on the bottom surface of the printed layer and overlapping the printed layer, and a third portion disposed between the first and second portions. In a plan view, the area of ​​the second portion may be smaller than the area of ​​the printed layer. A cover window including a hard coating layer may have improved mechanical robustness and improved reliability properties.

Description

[0001] Cross-references to related applications

[0002] This application claims priority and benefit to Korean Patent Application No. 10-2021-0037821, filed on March 24, 2021, with the Korean Intellectual Property Office, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a cover window including a hard coating, a method of manufacturing a cover window, and a display device including a cover window. Background Technology

[0004] Display devices include displays that can be used to show image information to users. Typically, a display device can display information within a given display screen. Display devices may also include covers that can be configured to protect internal components of the display device.

[0005] Cover windows may include polymer films, which can be easily damaged when exposed to external impacts. Therefore, it is desirable to improve the mechanical robustness of cover windows.

[0006] It should be understood that this background section is partly intended to provide useful context for understanding the art. However, this background section may also include ideas, concepts, or knowledge that were not known or understood by one of skill in the art prior to the relevant valid application date of the subject matter disclosed herein. Summary of the Invention

[0007] Embodiments of this disclosure provide a cover window with improved mechanical robustness and a display device including the cover window.

[0008] Embodiments of this disclosure provide a manufacturing method capable of improving the mechanical robustness of a cover window.

[0009] According to embodiments of this disclosure, the cover window may include a polymer film, a printed layer, and a hard coating layer. The printed layer is disposed below the polymer film. The hard coating layer includes a first portion disposed on the top surface of the polymer film and overlapping the polymer film, a second portion disposed on the bottom surface of the printed layer and overlapping the printed layer, and a third portion disposed between the first and second portions. In a plan view, the area of ​​the second portion may be smaller than the area of ​​the printed layer.

[0010] In this embodiment, the third part may contact the side surface of the polymer film and the side surface of the printed layer.

[0011] In one implementation, the third part may extend from one end of the first part.

[0012] In one embodiment, the edge of the polymer film may overlap with the edge of the printed layer.

[0013] In one embodiment, the polymer film may include a first polymer film having a first hardness and a second polymer film having a second hardness greater than the first hardness, wherein the second polymer film is disposed on the first polymer film.

[0014] In one embodiment, the first polymer film may include polycarbonate, and the second polymer film may include polymethyl methacrylate.

[0015] In some embodiments, the second polymer film may include a fluorinated compound.

[0016] In an embodiment, the polymer film may further include a third polymer film having a third hardness greater than the first hardness, and the third polymer film is disposed below the first polymer film.

[0017] In this embodiment, the thickness of the hard coating can be from about 5 μm to about 50 μm.

[0018] In one embodiment, the cover window may further include a sub-coating disposed between the polymer film and the printed layer. The hardness of the sub-coating may be less than that of the hard coating.

[0019] In one embodiment, the cover window may further include a sub-coating disposed between the polymer film and the printed layer. The thickness of the sub-coating may be less than the thickness of the hard coating.

[0020] According to embodiments of this disclosure, a method of manufacturing a cover window may include: providing a polymer film; providing a printed layer on a bottom surface of the polymer film; removing an edge portion of the polymer film, wherein the edge portion of the polymer film may not overlap with the printed layer; and providing a coating solution on a top surface of the polymer film to form a hard coating layer. The hard coating layer may include a first portion disposed on the top surface of the polymer film and overlapping the polymer film, a second portion disposed on the bottom surface of the printed layer and overlapping the printed layer, and a third portion disposed between the first and second portions. In a plan view, the area of ​​the second portion may be smaller than the area of ​​the printed layer.

[0021] In one embodiment, removing the edge portion of the polymer film may include removing a portion of the polymer film such that the edge of the polymer film can overlap with the edge of the printed layer.

[0022] In one embodiment, providing a polymer film may include providing a first polymer film having a first hardness and providing a second polymer film having a second hardness, wherein the second hardness may be greater than the first hardness.

[0023] In some embodiments, providing a polymer film may also include forming a sub-coating beneath the polymer film.

[0024] In one embodiment, forming a hard coating may include diffusing a coating solution from the top surface of the polymer film to the bottom surface of the printed layer.

[0025] In this embodiment, the coating solution may include a solid component, and the content of the solid component may be from about 30 wt% to about 50 wt%.

[0026] In embodiments, the coating solution may include at least one of methanol, isopropanol, isopropyl ether, acetone, methyl ethyl ketone, and propylene glycol methyl ether acetate.

[0027] According to embodiments of this disclosure, a display device may include a display panel and a cover window disposed on the display panel. The cover window may include a polymer film, a printed layer, and a hard coating layer. The printed layer is disposed below the polymer film. The hard coating layer includes a first portion disposed on the top surface of the polymer film and overlapping the polymer film, a second portion disposed on the bottom surface of the printed layer and overlapping the printed layer, and a third portion disposed between the first and second portions. In a plan view, the area of ​​the second portion may be smaller than the area of ​​the printed layer.

[0028] In this embodiment, the third part may contact the side surface of the polymer film and the side surface of the printed layer. Attached Figure Description

[0029] Exemplary embodiments will be more clearly understood from the following brief description taken in conjunction with the accompanying drawings. The drawings illustrate non-limiting exemplary embodiments as described herein.

[0030] Figure 1A This is a perspective view schematically showing a display device according to an embodiment of the present disclosure.

[0031] Figure 1B This is a perspective view schematically showing a display device according to an embodiment of the present disclosure.

[0032] Figure 2 It is along Figure 1A A schematic cross-sectional view taken from line I-I'.

[0033] Figure 3 This is a schematic cross-sectional view of the cover window according to an embodiment of the present disclosure.

[0034] Figure 4 This is an exploded perspective view schematically showing a portion of the cover window according to an embodiment of the present disclosure.

[0035] Figure 5 This is a schematic cross-sectional view of a display device according to an embodiment of the present disclosure.

[0036] Figure 6This is a schematic cross-sectional view of the cover window according to an embodiment of the present disclosure.

[0037] Figure 7 This is a schematic cross-sectional view of a portion of the cover window according to an embodiment of the present disclosure.

[0038] Figure 8 This is a schematic cross-sectional view of a portion of the cover window according to an embodiment of the present disclosure.

[0039] Figure 9 This is a schematic cross-sectional view of a portion of the cover window according to an embodiment of the present disclosure.

[0040] Figure 10 This is a flowchart schematically illustrating a method for manufacturing a cover window according to an embodiment of the present disclosure.

[0041] Figure 11 This is a schematic cross-sectional view illustrating a method of manufacturing a cover window according to an embodiment of the present disclosure.

[0042] Figure 12 This is a schematic cross-sectional view illustrating a method of manufacturing a cover window according to an embodiment of the present disclosure.

[0043] Figure 13 This is a schematic cross-sectional view illustrating a method of manufacturing a cover window according to an embodiment of the present disclosure.

[0044] Figure 14 This is a schematic cross-sectional view illustrating a method of manufacturing a cover window according to an embodiment of the present disclosure.

[0045] It should be noted that these figures are intended to illustrate the general characteristics of the methods, structures, and / or materials used in some exemplary embodiments and to supplement the written description provided below. However, these figures may not be drawn to scale and may not accurately reflect the precise structural or performance characteristics of any given embodiment, and should not be construed as limiting or restricting the range of values ​​or properties covered by the exemplary embodiments. For example, the relative thickness and positioning of molecules, layers, regions, and / or structural elements may be reduced or exaggerated for clarity. The use of similar or identical reference numerals in the figures is intended to indicate the presence of similar or identical elements or features. Detailed Implementation

[0046] Exemplary embodiments of the present disclosure will now be described more fully with reference to the accompanying drawings, in which exemplary embodiments are illustrated. However, exemplary embodiments of the present disclosure 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 the disclosure will be thorough and complete, and will fully convey the concept of the exemplary embodiments to those skilled in the art. In the drawings, the thickness of layers and regions may be exaggerated for clarity. The same reference numerals in the drawings denote the same elements, and therefore their description will be omitted.

[0047] It should be understood that the terms “connected to” or “linked to” can include physical or electrical connections or linkages. It should be understood that when an element is referred to as “connected” or “linked” to another element, it may be directly connected to or linked to the other element, or there may be an intervening element. Conversely, when an element is referred to as “directly connected” or “directly linked” to another element, there may be no intervening element. Other terms used to describe relationships between elements or layers should be interpreted in a similar manner (e.g., “between” vs. “directly between”, “adjacent” vs. “directly adjacent”, “on” vs. “directly on”).

[0048] The same reference numerals always denote the same elements. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. For example, "A and / or B" can be understood to mean "A, B, or A and B". The terms "and" and "or" can be used in a combined or separate sense and can be understood as equivalent to "and / or". In the specification and claims, for purposes of meaning and interpretation, the phrase "at least one of..." is intended to include the meaning of "at least one selected from...". For example, "at least one of A and B" can be understood to mean "A, B, or A and B".

[0049] It should be understood that although the terms "first," "second," etc., may be used herein to describe various elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms are used only to distinguish one element, component, region, layer, or segment from another element, component, region, layer, or segment. Therefore, without departing from the teachings of the exemplary embodiments, the first element, first component, first region, first layer, or first segment discussed below may be referred to as a second element, second component, second region, second layer, or second segment.

[0050] For ease of description, spatial relative terms such as “below,” “under,” “lower,” “above,” and “upper” may be used herein to describe the relationship between one element or feature as shown in the accompanying drawings and another element(s). It should be understood that, in addition to the orientation shown in the accompanying drawings, spatial relative terms may be intended to also include different orientations of the device during use or operation. For example, if the device in the accompanying drawings is flipped, the element described as “below” or “under” other elements or features will be oriented accordingly to be “above” other elements or features. Thus, the term “below” can include both above and below orientations. The device may be otherwise oriented (rotated 90 degrees or in other orientations), and the spatial relative descriptive terms used herein should be interpreted accordingly.

[0051] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well (and vice versa), unless the context clearly indicates otherwise. It will also be understood that, if used herein, the terms “comprises,” “comprising,” “includes,” and / or “including” specify the presence of the described features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or groups thereof.

[0052] Exemplary embodiments of this disclosure are described herein with reference to schematic cross-sectional views of idealized embodiments (and intermediate structures) as exemplary implementations. Thus, variations in the shape of the illustrations due to, for example, manufacturing techniques and / or tolerances are to be expected. Therefore, exemplary embodiments of this disclosure should not be construed as limited to specific shapes of the areas shown herein, but should include, for example, shape deviations due to manufacturing processes.

[0053] The terms "overlapping" or "overlapped" mean that a first object may be above or below a second object or on one side of a second object, and conversely, a second object may be above or below a first object or on one side of a first object. Additionally, the term "overlapping" may include layer, stack, face or facing, extending above, extending below, covering or partially covering, or any other suitable term as will be understood and appreciated by those skilled in the art. The terms "face" and "facing" mean that a first element may be directly or indirectly opposite a second element. In the case where a third element is located between the first and second elements, the first and second elements may be understood as indirectly opposite each other, but still facing each other. When an element is described as not "overlapping" or "overlapping" with another element, it may include elements spaced apart from each other, offset from each other, or arranged side by side, or any other suitable term as will be understood and appreciated by those skilled in the art.

[0054] As used herein, terms such as “about,” “approximately,” and “substantially” include the stated value and mean within an acceptable range of deviation from the stated value, as determined by a person skilled in the art, taking into account the measurement under discussion and the errors associated with the measurement of the particular quantity (i.e., limitations of the measurement system). For example, “about” may mean within one or more standard deviations of the stated value, or within ±30%, ±20%, ±10%, ±5%.

[0055] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which the exemplary embodiments of this disclosure pertain. It should also be understood that terms such as those defined in common dictionaries should be interpreted as having meanings consistent with their meanings in the context of the relevant field and will not be interpreted as having idealized or overly formal meanings unless expressly defined herein.

[0056] Figure 1A and Figure 1B This is a schematic perspective view of a display device DD or DD-a according to an embodiment of the present disclosure. The display device DD or DD-a according to an embodiment of the present disclosure can be a device that can be activated by an electrical signal applied to it. For example, the display device DD or DD-a can be a cellular phone, tablet computer, car navigation system, game console, or wearable device, but is not limited to these examples. Figure 1A An example is shown where the display device DD can be a cellular phone.

[0057] refer to Figure 1AThe display device DD may include an active region AA-DD that can be used to display an image IM. The active region AA-DD may include a flat surface defined by a first directional axis DR1 and a second directional axis DR2. The active region AA-DD may also include a curved surface that can be bent or extended in a curved manner from at least one side edge of the flat surface defined by the first directional axis DR1 and the second directional axis DR2. Figure 1A The display device DD illustrates an example in which the display device DD has two curved surfaces that can extend from opposite side surfaces of a flat surface. However, the shape of the active regions AA-DD is not limited to this example. In one embodiment, the active regions AA-DD may have only a flat surface. In other embodiments, the active regions AA-DD may have four curved surfaces that can extend from the four side surfaces of the flat surface, respectively.

[0058] In one embodiment, the display device DD may be flexible. Here, the term "flexible" will be used to express that the display device DD may be highly bendable or foldable, sufficient to have a radius of curvature ranging from a few angstroms to a few centimeters. For example, the display device DD may be a foldable display device. In other embodiments, the display device DD may be a rigid display device.

[0059] The thickness direction of the display device DD can be parallel to a third directional axis DR3, which can be perpendicular to the flat surface defined by the first directional axis DR1 and the second directional axis DR2. In this specification, the directions indicated by the first directional axis DR1, the second directional axis DR2, and the third directional axis DR3 can be relative concepts, and in embodiments, they can be changed to indicate other directions. The directions indicated by the first directional axis DR1, the second directional axis DR2, and the third directional axis DR3 can be referred to as the first direction to the third direction and will be identified using the same reference numerals. In this specification, the first directional axis DR1 and the second directional axis DR2 can be perpendicular to each other, and the third directional axis DR3 can be a normal direction that is perpendicular to the flat surface defined by the first directional axis DR1 and the second directional axis DR2.

[0060] The active area AA-DD of the display device DD can define a sensing area SA-DD. Figure 1A An example is shown where a sensing area SA-DD can be set, but the number of sensing areas SA-DD is not limited to one. The sensing area SA-DD can be a portion of the active area AA-DD. The display device DD can display an image through the sensing area SA-DD.

[0061] and Figure 1A The examples are different. Figure 1BAn example is shown in which a game console can be used as a display device DD-a. The display device DD-a may include a display area DA and a non-display area NDA that may be disposed adjacent to the display area DA. The display area DA can display an image IM-a. The display area DA may include a flat surface defined by a first directional axis DR1 and a second directional axis DR2. The non-display area NDA may be surrounded by the display area DA. The shapes of the display area DA and the non-display area NDA may change differently in a mutually influential manner.

[0062] Buttons BN1 and BN2 can be located in the non-display area NDA. Buttons BN1 and BN2 can be used to operate the display device DD-a. In one embodiment, at least one first button BN1 and at least one second button BN2 can be provided in the display device DD-a. In other embodiments, one of the first button BN1 and the second button BN2 can be omitted. The first button BN1 can be cross-shaped, and the second button BN2 can be circular. However, this disclosure is not limited to this example, and the shapes of buttons BN1 and BN2 can be varied. Unlike the structure shown in the figures, buttons BN1 and BN2 can be located in the display area DA. The technical features of the display device DD or DD-a described below can be applied in the same way. Figure 1A Display devices DD and Figure 1B The display device DD-a.

[0063] Figure 2 It is along Figure 1A The diagram is a schematic cross-sectional view taken by line I-I' to illustrate a display device DD or DD-a according to an embodiment of the present disclosure. The display device DD or DD-a may include a display panel DP and a cover window WD that may be disposed on the display panel DP. The display device DD or DD-a may include a housing HU disposed below the display panel DP. The display panel DP may be housed within the housing HU.

[0064] The display panel DP may include a base layer BS, a circuit layer DP-CL disposed on the base layer BS, and an emitting element layer DP-ED disposed on the circuit layer DP-CL.

[0065] The base layer BS can be a glass substrate, a metal substrate, a plastic substrate, or a combination thereof. However, this disclosure is not limited to this example, and the base layer BS can be an inorganic layer, an organic layer, or a layer made of composite materials.

[0066] The circuit layer DP-CL can be disposed on the base layer BS and can include transistors (not shown). Each of the transistors (not shown) may include a control electrode, an input electrode, and an output electrode. For example, the circuit layer DP-CL may include switching transistors and driving transistors that can be used to operate or drive the emitter element (not shown) of the emitter element layer DP-ED.

[0067] The emitting element layer DP-ED may include emitting elements. Each of the emitting elements may include a first electrode and a second electrode that can be arranged facing each other, and a light-emitting layer that can be disposed between the first electrode and the second electrode. Although not shown, an encapsulation layer may be disposed on the emitting element layer DP-ED, and in embodiments, the encapsulation layer may be disposed to hermetically seal the emitting element layer DP-ED.

[0068] An optical layer PP may be disposed between the display panel DP and the cover window WD. The optical layer PP may be disposed on the display panel DP to control light reflection on the display panel DP caused by external light. For example, the optical layer PP may include a polarizing layer or a color filter layer. However, this disclosure is not limited to this example, and in embodiments, the optical layer PP may be omitted.

[0069] Adhesive layers AL1 and AL2 may be provided between the display panel DP and the optical layer PP, and between the optical layer PP and the cover window WD. Adhesive layers AL1 and AL2 may be optically transparent. Adhesive layers AL1 and AL2 may be formed of at least one of optically transparent adhesive (OCA), optically transparent resin (OCR), and pressure-sensitive adhesive (PSA), or may include at least one of these three adhesives. The optical layer PP and the cover window WD can be bonded to each other via the first adhesive layer AL1. The display panel DP and the optical layer PP can be bonded to each other via the second adhesive layer AL2. In embodiments, although not shown, at least one of the first adhesive layer AL1 and the second adhesive layer AL2 may be omitted.

[0070] Figure 3 This schematically illustrates a cover window WD (e.g., according to an embodiment of the present disclosure). Figure 2 A cross-sectional view of the detailed structure of the WD cover window. (See reference) Figure 3 The cover window WD according to embodiments of the present disclosure may include a polymer film PL, a printed layer BM, and a hard coating CA.

[0071] The polymer film PL may include a first polymer film PL-1 and a second polymer film PL-2 that may be disposed on the first polymer film PL-1. The first polymer film PL-1 may have a first hardness, and the second polymer film PL-2 may have a second hardness. The second hardness may be greater than the first hardness. The second polymer film PL-2, which may be placed at a higher level in the thickness direction, may have a greater hardness than the first polymer film PL-1, which is placed at a lower level. The modulus of the second polymer film PL-2 may be greater than the modulus of the first polymer film PL-1. The thickness of the first polymer film PL-1 may be greater than the thickness of the second polymer film PL-2. However, this disclosure is not limited to this example, and the hardness, modulus, and thickness of at least one of the first polymer film PL-1 and the second polymer film PL-2 may be varied differently.

[0072] In this embodiment, the first polymer film PL-1 may be formed of or comprise polycarbonate (PC), and the second polymer film PL-2 may be formed of or comprise polymethyl methacrylate (PMMA). Furthermore, the second polymer film PL-2 may also comprise a fluorinated compound. The second polymer film PL-2 may also comprise a material that can be used to achieve the anti-fingerprint function. However, this disclosure is not limited to this example, and the materials used for the first polymer film PL-1 and the second polymer film PL-2 are not limited thereto.

[0073] In this embodiment, one of the first polymer film PL-1 and the second polymer film PL-2 may be omitted. The polymer film PL may be a single layer made of a single material or several materials. For example, the polymer film PL may be formed from at least one of polyimide (PI), polyethylene terephthalate (PET), polyurethane (PU), and triacetyl cellulose (TAC), or may include at least one of polyimide (PI), polyethylene terephthalate (PET), polyurethane (PU), and triacetyl cellulose (TAC). The polymer film PL may be optically transparent.

[0074] The printed layer BM can be positioned below the polymer film PL. The edge PL-ED of the polymer film PL can overlap with the edge BM-ED of the printed layer BM. The edges PL-ED of the polymer film PL and BM-ED of the printed layer BM can be parallel to the third directional axis DR3.

[0075] The printed layer BM can be disposed adjacent to the first polymer film PL-1. The printed layer BM can be disposed below the first polymer film PL-1. The second polymer film PL-2 and the printed layer BM can be spaced apart from each other, and the first polymer film PL-1 is interposed between the second polymer film PL-2 and the printed layer BM. The printed layer BM can be formed to include an organic or inorganic light-blocking material, which may include a black pigment or dye. However, this disclosure is not limited to this example, and a printed layer BM having a non-black color can also be provided.

[0076] In this embodiment, the hard coating CA may include at least two portions that may be located near the printed layer BM and the polymer film PL, respectively. The hard coating CA may include a first portion CA-A1, a second portion CA-A2, and a third portion CA-A3. The first portion CA-A1, the second portion CA-A2, and the third portion CA-A3 of the hard coating CA may be a single object. The first portion CA-A1, the second portion CA-A2, and the third portion CA-A3 of the hard coating CA may be formed by a single process.

[0077] The first portion CA-A1 of the hard coating CA can be disposed on the top surface of the polymer film PL. The first portion CA-A1 can be an element that completely overlaps with the top surface of the polymer film PL. The first portion CA-A1 of the hard coating CA can cover the top surface of the polymer film PL. More specifically, the first portion CA-A1 of the hard coating CA can cover the top surface of the second polymer film PL-2. In other embodiments, if the second polymer film PL-2 is omitted, the hard coating CA can be configured to cover the top surface of the first polymer film PL-1. When viewed in cross-sectional view, the first portion CA-A1 can extend in a direction parallel to the second direction axis DR2.

[0078] When viewed in a sectional view, the second portion CA-A2 of the hard coating CA may extend in a direction parallel to the second direction axis DR2. When viewed in a plan view, the first portion CA-A1 and the second portion CA-A2 may be parallel to a flat surface defined by the first direction axis DR1 and the second direction axis DR2. The second portion CA-A2 of the hard coating CA may be disposed on the bottom surface of the printed layer BM. The second portion CA-A2 of the hard coating CA may cover at least a portion of the printed layer BM. The second portion CA-A2 of the hard coating CA may contact the bottom surface of the printed layer BM. The second portion CA-A2 may overlap at least a portion of the bottom surface of the printed layer BM. The bottom surface and the top surface of the printed layer BM may be spaced apart from each other in a direction parallel to the third direction axis DR3. The top surface of the printed layer BM may be adjacent to the polymer film PL.

[0079] The third portion CA-A3 of the hard coating CA can be disposed between the first portion CA-A1 and the second portion CA-A2. One end of the third portion CA-A3 can be placed adjacent to the first portion CA-A1, and the other end of the third portion CA-A3 can be placed adjacent to the second portion CA-A2. The third portion CA-A3 can be an element that can extend from one end of the first portion CA-A1. The second portion CA-A2 can extend from the third portion CA-A3. The third portion CA-A3 can extend in a direction parallel to the third directional axis DR3. The third portion CA-A3 can cover the side surface PL-SF of the polymer film PL and the side surface BM-SF of the printed layer BM. The third portion CA-A3 can contact the side surface PL-SF of the polymer film PL and the side surface BM-SF of the printed layer BM.

[0080] The hard coating CA can have a hardness greater than that of the polymer film PL. The modulus of the hard coating CA can be higher than that of the polymer film PL. More specifically, the modulus of the hard coating CA can be greater than that of the first polymer film PL-1 and the second polymer film PL-2.

[0081] The third part, CA-A3, can be used to improve the mechanical robustness of the side surface of the cover glass WD. The hard coating CA can cover at least a portion of the printed layer BM and the polymer film PL. The second part, CA-A2, of the hard coating CA can protect the printed layer BM. In the event of an external impact applied to the printed layer BM located below the polymer film PL, the printed layer BM may detach from the polymer film PL. In the event of an external impact applied to the printed layer BM that can be disposed adjacent to the first polymer film PL-1 (whose hardness may be less than that of the second polymer film PL-2), the printed layer BM may detach from the polymer film PL. The second part, CA-A2, can protect the printed layer BM from external impacts. Since the second part, CA-A2, can be configured to cover at least a portion of the printed layer BM, detachment of the printed layer BM from the polymer film PL can be prevented.

[0082] The third portion CA-A3 can be configured to cover the side surface PL-SF of the polymer film PL, and therefore, the third portion CA-A3 can protect the polymer film PL from external impacts. The exposed area of ​​the side surface PL-SF of the polymer film PL can be larger in the first polymer film PL-1 than in the second polymer film PL-2. As described above, since the thickness of the first polymer film PL-1 can be greater than the thickness of the second polymer film PL-2, the first polymer film PL-1 can be exposed in a relatively large area. Since the first polymer film PL-1 can have a lower hardness than the second polymer film PL-2, the first polymer film PL-1 may be easily damaged by external impacts. Since the side surface PL-SF of the polymer film PL can be covered by the third portion CA-A3 of the hard coating CA, the polymer film PL can be protected from external impacts. Therefore, the cover window WD according to the embodiments of this disclosure can have improved mechanical robustness properties. This can improve the reliability of the display device DD or DD-a including the cover window WD.

[0083] In this embodiment, the hard coating CA can have thicknesses T1, T2, and T3 of about 5 μm to about 50 μm. When the thickness of the hard coating is less than about 5 μm, it may be difficult to improve the mechanical robustness of the cover window. Conversely, when the thickness of the hard coating is greater than about 50 μm, the cover window may have a significantly increased thickness, and the display device may also have an increased thickness.

[0084] The thickness T1 of the first portion CA-A1 and the thickness T2 of the second portion CA-A2 can be values ​​measured in a direction parallel to the third direction axis DR3. The thickness T3 of the third portion CA-A3 can be a value measured in a direction parallel to the second direction axis DR2. The thickness T1 of the first portion CA-A1 can be from about 5 μm to about 50 μm. The thickness T2 of the second portion CA-A2 can be from about 5 μm to about 50 μm. The thickness T3 of the third portion CA-A3 can be from about 5 μm to about 50 μm. The thickness T1 of the first portion CA-A1, the thickness T2 of the second portion CA-A2, and the thickness T3 of the third portion CA-A3 can have the same value. In other embodiments, at least one of the thickness T1 of the first portion CA-A1, the thickness T2 of the second portion CA-A2, and the thickness T3 of the third portion CA-A3 can be different from each other. Even in this case, such differences in thickness can be within the range of measurement error.

[0085] Figure 4The diagram schematically illustrates an exploded perspective view of the hard coating CA and the printed layer BM. To reduce complexity and provide a better understanding of exemplary embodiments of this disclosure, the hard coating CA is shown as having only a second portion CA-A2 in contact with the printed layer BM. On a flat surface defined by a first direction axis DR1 and a second direction axis DR2, the area of ​​the second portion CA-A2 of the hard coating CA may be less than or equal to the area of ​​the printed layer BM. On a flat surface defined by the first direction axis DR1 and the second direction axis DR2, the area of ​​the second portion CA-A2 may be equal to the area of ​​the printed layer BM. In other embodiments, on a flat surface defined by the first direction axis DR1 and the second direction axis DR2, the area of ​​the second portion CA-A2 may be less than the area of ​​the printed layer BM. For example, on a flat surface defined by the first direction axis DR1 and the second direction axis DR2, the area of ​​the second portion CA-A2 may be from about 10% to about 90% of the area of ​​the printed layer BM. More specifically, on a flat surface defined by the first direction axis DR1 and the second direction axis DR2, the area of ​​the second portion CA-A2 may be about 50% of the area of ​​the printed layer BM. When the area of ​​the second part CA-A2 is in the range of approximately 10% to approximately 90% of the area of ​​the printed layer BM, the hard coating CA may be unable to pass through the active region AA-DD (e.g., see...). Figure 1A This can be identified and can protect the printed layer BM from external impacts. However, this disclosure is not limited to this example, and the ratio of the area of ​​the second part CA-A2 to the area of ​​the printed layer BM can be varied.

[0086] Figure 5 Another example of a covered window (i.e., covered window WD-a) is illustrated schematically, and Figure 6 It shows Figure 5 Detailed structure of the WD-a cover window. (Compared to...) Figure 2 and Figure 3 The structures shown are different. Figure 5 and Figure 6 The WD-a cover can also include a sub-coating S-CA.

[0087] According to an embodiment, a sub-coating S-CA may be disposed between the polymer film PL and the printed layer BM. The sub-coating S-CA may be disposed below the polymer film PL. The sub-coating S-CA may be a component whose hardness is lower than that of the hard coating CA. The hardness of the sub-coating S-CA may be less than that of the hard coating CA. The hard coating CA, which may be placed at a higher level in the thickness direction, may have a hardness greater than that of the sub-coating S-CA. The hard coating CA, which may be placed at the upper level of the display device DD or DD-a, may have a hardness greater than that of the sub-coating S-CA. In other embodiments, the hardness of the sub-coating S-CA may be equal to the hardness of the hard coating CA.

[0088] The thickness T4 of the sub-coating S-CA can be less than or equal to the thicknesses T1, T2, and T3 of the hard coating CA. The thickness T4 of the sub-coating S-CA can be less than the thicknesses T1, T2, and T3 of the hard coating CA. The thickness T4 of the sub-coating S-CA can be less than at least one of the thicknesses T1 of the first portion CA-A1, T2 of the second portion CA-A2, and T3 of the third portion CA-A3. In other embodiments, the thickness T4 of the sub-coating S-CA can be equal to the thicknesses T1, T2, and T3 of the hard coating CA. The thickness T4 of the sub-coating S-CA can be equal to at least one of the thicknesses T1 of the first portion CA-A1, T2 of the second portion CA-A2, and T3 of the third portion CA-A3. The thickness T4 of the sub-coating S-CA can be equal to all of the thicknesses T1 of the first portion CA-A1, T2 of the second portion CA-A2, and T3 of the third portion CA-A3.

[0089] In embodiments, the hard coating CA can be formed from at least one of an organic compound and an organic / inorganic composite compound, or include at least one of an organic compound and an organic / inorganic composite compound. The organic compound may include acrylic compounds, epoxy compounds, or combinations thereof, and the organic / inorganic compound may include silicon compounds.

[0090] Figures 7 to 9 This is a schematic cross-sectional view illustrating some examples of polymer films (i.e., polymer films PL-a, PL-b, and PL-c) according to embodiments of the present disclosure. In embodiments, three or more polymer films may be arranged in a stacked configuration in polymer films PL-a, PL-b, and PL-c. In addition to the first polymer film PL-1 and the second polymer film PL-2, polymer films PL-a, PL-b, and PL-c may also comprise one or more polymer films. The following... Figures 7 to 9 In the description, the same polymer film can be identified with the same reference numerals without repeating its overlapping description. Figures 7 to 9 The polymer films PL-a, PL-b, and PL-c can have the same properties as... Figure 3 and Figure 6 The polymer film PL has essentially the same characteristics.

[0091] refer to Figure 7The polymer film PL-a may include a first polymer film PL-1, a second polymer film PL-2, and a third polymer film PL-3. The third polymer film PL-3 may be disposed below the first polymer film PL-1. The third polymer film PL-3, the first polymer film PL-1, and the second polymer film PL-2 may be stacked sequentially on top of each other. The third polymer film PL-3 may have a third hardness, which may be greater than the first hardness of the first polymer film PL-1. The thickness of the third polymer film PL-3 may be less than the thickness of the first polymer film PL-1. The third polymer film PL-3 may protect the first polymer film PL-1. Because the third polymer film PL-3 may have a greater hardness than the first polymer film PL-1, it may have better impact resistance than the first polymer film PL-1. The printed layer BM may be disposed below the third polymer film PL-3. The sub-coating S-CA may be disposed between the third polymer film PL-3 and the printed layer BM. In other embodiments, the sub-coating S-CA may be omitted between the third polymer film PL-3 and the printed layer BM. For example, the third polymer membrane PL-3 and the second polymer membrane PL-2 can be formed of the same material or comprise the same material. The third polymer membrane PL-3 and the second polymer membrane PL-2 can be formed of polymethyl methacrylate or comprise polymethyl methacrylate.

[0092] Figure 8 The polymer film PL-b may further include a third polymer film PL-3 and a fourth polymer film PL-4. The third polymer film PL-3 may be disposed below the first polymer film PL-1, and the fourth polymer film PL-4 may be disposed below the third polymer film PL-3. The fourth polymer film PL-4 and the first polymer film PL-1 may be spaced apart from each other, and the third polymer film PL-3 is inserted between the fourth polymer film PL-4 and the first polymer film PL-1. The printed layer BM may be disposed below the fourth polymer film PL-4, and the sub-coating S-CA may be disposed between the fourth polymer film PL-4 and the printed layer BM. In other embodiments, it is possible to obtain...

[0093] The sub-coating S-CA is omitted in the region between the fourth polymer film PL-4 and the printed layer BM. The fourth polymer film PL-4 may have a fourth hardness, and the fourth hardness of the fourth polymer film PL-4 may be less than the third hardness of the third polymer film PL-3. The thickness of the fourth polymer film PL-4 may be greater than the thickness of the third polymer film PL-3. The fourth polymer film PL-4 and the first polymer film PL-1 may be formed of the same material or comprise the same material. For example, the fourth polymer film PL-4 and the first polymer film PL-1 may be formed of polycarbonate or comprise polycarbonate.

[0094] Figure 9The polymer film PL-c may further include a third polymer film PL-3, a fourth polymer film PL-4, and a fifth polymer film PL-5. The fifth polymer film PL-5 may be disposed below the fourth polymer film PL-4. The fifth polymer film PL-5, the fourth polymer film PL-4, the third polymer film PL-3, the first polymer film PL-1, and the second polymer film PL-2 may be stacked sequentially on top of each other. The printed layer BM may be disposed below the fifth polymer film PL-5. The sub-coating S-CA may be disposed between the fifth polymer film PL-5 and the printed layer BM. In other embodiments, the sub-coating S-CA may be omitted.

[0095] The fifth polymer film PL-5 can have a fifth hardness, and the fifth hardness of the fifth polymer film PL-5 can be greater than the fourth hardness of the fourth polymer film PL-4. The thickness of the fifth polymer film PL-5 can be less than the thickness of the fourth polymer film PL-4. The fifth polymer film PL-5 can protect the fourth polymer film PL-4. Because the fifth polymer film PL-5 can have a greater hardness than the fourth polymer film PL-4, it can therefore have better impact resistance than the fourth polymer film PL-4. For example, the fifth polymer film PL-5 and the third polymer film PL-3 can be formed from the same material, or comprise the same material. The fifth polymer film PL-5 and the third polymer film PL-3 can be formed from polymethyl methacrylate, or comprise polymethyl methacrylate.

[0096] In an embodiment, the display device DD or DD-a may include a display panel DP and a cover window WD or WD-a disposed on the display panel DP. The cover window WD or WD-a may include a polymer film PL, a printed layer BM, and a hard coating CA. The hard coating CA may be disposed to cover at least a portion of the printed layer BM and the polymer film PL, thereby protecting the polymer film PL and the printed layer BM from external impacts. Therefore, the cover window WD or WD-a may exhibit improved hardness or strength properties. This can improve the reliability of the display device DD or DD-a.

[0097] Figure 10 This is a flowchart schematically illustrating a method for manufacturing a cover window according to an embodiment of the present disclosure. Figures 11 to 14 The process of manufacturing a cover window according to an embodiment of the present disclosure is illustrated schematically. In the following... Figures 10 to 14 For the sake of brevity, the previous references in the description are omitted. Figures 2 to 9 The described elements may be identified using the same reference numerals, without repeating their overlapping descriptions.

[0098] According to embodiments of the present disclosure, a method for manufacturing a cover window may include: providing a polymer film (in S100); providing a printed layer (in S200); removing edge portions of the polymer film (in S300); and forming a hard coating (in S400).

[0099] The polymer film PL may include a first polymer film PL-1 and a second polymer film PL-2 that may be disposed on the first polymer film PL-1. The first hardness of the first polymer film PL-1 may be less than the second hardness of the second polymer film PL-2. In an embodiment, providing the polymer film (in S100) may include forming a sub-coating S-CA beneath the polymer film PL. The sub-coating S-CA can be formed by providing a sub-coating solution on the bottom surface of the polymer film PL. In an embodiment, the formation of the sub-coating S-CA may be omitted.

[0100] The printed layer BM can be disposed beneath the polymer film PL. For example, the printed layer BM can be formed by depositing an organic or inorganic light-blocking material, including a black pigment or dye, onto the bottom surface of the polymer film PL. The printed layer BM can be formed by a printing process. However, this disclosure is not limited to this example, and the printed layer BM can be formed from various materials or by various methods.

[0101] It is possible to remove portions of the polymer film PL. For example, it is possible to remove the edge portions of the polymer film PL that do not overlap with the printed layer BM. (Reference) Figure 11 The process can remove edge portions of the polymer film PL, allowing the new edge of the polymer film PL to align with the edge BM-ED of the printed layer BM. For example, the edge portion of the polymer film PL can be removed along a first processing line CT1 that can be parallel to the edge BM-ED of the printed layer BM. The first processing line CT1 can be parallel to the thickness direction. The edge portion of the polymer film PL can be removed using a computer numerical control (CNC) process. The edge portion of the sub-coating S-CA, which may be located below the polymer film PL, can also be removed. After partial removal of the polymer film PL, the edge PL-ED of the polymer film PL can overlap or align with the edge BM-ED of the printed layer BM. The edges PL-ED of the polymer film PL and BM-ED of the printed layer BM can be parallel to the thickness direction.

[0102] After removing the edge portions of the polymer film PL (in S300), a hard coating can be formed (in S400). A coating solution CS can be provided on the top surface PL-UF of the polymer film PL. The coating solution CS can be provided via a nozzle NZ (e.g., a die). In other embodiments, the coating solution CS can be provided via a jetting or inkjet process. However, this disclosure is not limited to this example, and the method of providing the coating solution CS can be varied.

[0103] The coating solution CS can cover at least a portion of the bottom surface BM-DF of the printed layer BM. The coating solution CS can also cover the top surface PL-UF of the polymer film PL and the side surface PL-SF of the polymer film PL (e.g., Figure 3 ) and the side surface BM-SF of the printed layer BM (e.g., Figure 3 The coating solution CS can be transferred to the bottom surface BM-DF of the printed layer BM.

[0104] A protective film CM can be placed under the printed layer BM to protect the polymer film PL and the printed layer BM. The protective film CM can be removed after the manufacturing process.

[0105] In this embodiment, the protective film CM may be configured to partially contact the printed layer BM. Furthermore, the protective film CM may partially contact the sub-coating S-CA. If the sub-coating S-CA is omitted, the protective film CM may partially contact the polymer film PL. For example, the protective film CM may partially contact the first polymer film PL-1. In this embodiment, the protective film CM may be provided to form a space GA between the protective film CM and the bottom surface BM-DF of the printed layer BM. Therefore, a coating solution CS may be supplied into the space GA between the protective film CM and the printed layer BM. For example, the coating solution CS may be transferred from the top surface PL-UF of the polymer film PL to the bottom surface BM-DF of the printed layer BM.

[0106] A coating solution CS can be transferred to cover at least a portion of the bottom surface BM-DF of the printed layer BM. The transferred coating solution CS can form a hard coating CA. After transferring the coating solution CS, a portion of the hard coating CA can be removed. For example, the removal of a portion of the hard coating CA can be performed along a second processing line CT2 parallel to the edge portion of the printed layer BM. The second processing line CT2 can be parallel to the thickness direction. A portion of the hard coating CA that does not contact the polymer film PL, the printed layer BM, or the sub-coating S-CA can be removed, and due to this process, the cover window WD or WD-a can be formed with the desired dimensions.

[0107] The coating solution CS may include at least one of an organic compound and an organic / inorganic composite compound. The organic compound may include acrylic compounds, epoxy compounds, or combinations thereof, and the organic / inorganic compound may include a silicon compound. For example, the coating solution CS may include at least one of methanol, isopropanol (IPA), isopropyl ether (IPE), acetone, methyl ethyl ketone (MEK), and propylene glycol methyl ether acetate (PGMEA). However, the materials used for the coating solution CS are not limited to these examples.

[0108] The coating solution CS may include solid components in an amount of about 30 wt% to about 50 wt%. If the solid component content in the coating solution is less than about 30 wt%, the coating solution may have low viscosity and may behave as a highly fluid liquid. It may be difficult to uniformly form a hard coating. If the solid component content in the coating solution is greater than about 50 wt%, the coating solution may have high viscosity and may behave as a highly viscous substance. It is difficult to supply the coating solution to the area below the printed layer and thereby form a hard coating. Moreover, if the coating solution includes a solid component content greater than about 50 wt%, the coating solution may be unsuitable for solution processes. In this embodiment, since the coating solution CS includes about 30 wt% to about 50 wt% solid components, the coating solution CS can be used to uniformly form a hard coating CA and can be effectively used in solution processes.

[0109] The area of ​​the hard coating CA can be controlled by adjusting the content of the solid components included in the coating solution CS. By adjusting the solid component content, the area of ​​the second portion CA-A2 of the hard coating CA, which overlaps with at least a portion of the bottom surface BM-DF of the printed layer BM, can be controlled. When the solid component content is low, the coating solution CS can be easily supplied to the bottom surface BM-DF of the printed layer BM, reducing the area difference between the second portion CA-A2 and the bottom surface BM-DF of the printed layer BM. Conversely, when the solid component content is high, the coating solution CS can have a high viscosity, and therefore, the second portion CA-A2 can be formed with an area that can be smaller than the area of ​​the bottom surface BM-DF of the printed layer BM.

[0110] According to embodiments of this disclosure, a cover window may include a polymer film, a printed layer, and a hard coating layer. The hard coating layer may include a first portion, a second portion, and a third portion. The first portion may be configured to completely overlap the polymer film, the second portion may overlap at least a portion of the bottom surface of the printed layer, and the third portion may be disposed between the first and second portions. The hard coating layer can protect the polymer film and the printed layer from external impacts, and therefore, the cover window can have improved mechanical robustness properties.

[0111] According to embodiments of this disclosure, a display device may include a display panel and a cover window on the display panel. The cover window may include a hard coating and may have improved mechanical robustness properties. Therefore, the reliability of the display device can be improved.

[0112] According to embodiments of this disclosure, a method of manufacturing a cover window may include: providing a polymer film; providing a printed layer on a bottom surface of the polymer film; and providing a coating solution on a top surface of the polymer film to form a hard coating. The hard coating may include a first portion, a second portion, and a third portion, and the hard coating may be configured to cover at least a portion of the printed layer and the polymer film. Cover windows manufactured by this method may exhibit improved mechanical robustness properties.

[0113] According to embodiments of this disclosure, the cover window and the display device having the cover window may include a hard coating, and they may have improved hardness or strength properties.

[0114] According to embodiments of this disclosure, a method of manufacturing a cover window may include forming a hard coating, and the cover window may be manufactured to have improved hardness or strength properties.

[0115] While exemplary embodiments of this disclosure have been specifically shown and described, those skilled in the art will understand that variations in form and detail may be made therein without departing from the spirit and scope of the appended claims (including their equivalents).

Claims

1. Window covering, including: A polymer film, comprising a first polymer film and a second polymer film disposed on the first polymer film; A printed layer is disposed beneath the polymer film; as well as Hard coatings, including: The first part is disposed on the top surface of the polymer film and overlaps with the polymer film; The second part is disposed on the bottom surface of the printed layer and overlaps with the printed layer; and The third part is located between the first part and the second part. In the plan view, the area of ​​the second portion is less than or equal to the area of ​​the printed layer, and the edge of the polymer film overlaps with the edge of the printed layer. The modulus of the second polymer film is greater than that of the first polymer film, and the thickness of the second polymer film is less than that of the first polymer film.

2. The cover window of claim 1, wherein, The third part contacts the side surface of the polymer film and the side surface of the printed layer.

3. The cover window of claim 1, wherein, The third part extends from one end of the first part.

4. The window cover according to claim 1, wherein, The first polymer film has a first hardness; and The second polymer film has a second hardness greater than the first hardness.

5. The window cover according to claim 4, wherein, The first polymer film comprises polycarbonate, and The second polymer film comprises polymethyl methacrylate.

6. The cover window of claim 4, wherein, The second polymer film comprises a fluorinated compound.

7. The cover window of claim 4, wherein, The polymer film further includes a third polymer film, which has a third hardness greater than the first hardness, and the third polymer film is disposed below the first polymer film.

8. The window cover according to claim 1, further comprising: A sub-coating is disposed between the polymer film and the printed layer. The hardness of the sub-coating is less than that of the hard coating.

9. Methods for manufacturing window covers, including: A polymer membrane is provided, wherein the polymer membrane includes a first polymer membrane and a second polymer membrane disposed on the first polymer membrane; A printed layer is provided on the bottom surface of the polymer film; Remove the edge portions of the polymer film, wherein the edge portions of the polymer film do not overlap with the printed layer; and A coating solution is provided on the top surface of the polymer film to form a hard coating, wherein the hard coating comprises: The first part is disposed on the top surface of the polymer film and overlaps with the polymer film; The second part is disposed on the bottom surface of the printed layer and overlaps with the printed layer; and The third part is positioned between the first part and the second part, and In the plan view, the area of ​​the second portion is less than or equal to the area of ​​the printed layer. The removal of the edge portion of the polymer film includes: Remove a portion of the polymer film such that the edge of the polymer film overlaps with the edge of the printed layer, and The modulus of the second polymer film is greater than that of the first polymer film, and the thickness of the second polymer film is less than that of the first polymer film.

10. The method of claim 9, wherein, Providing the polymer film also includes forming a sub-coating beneath the polymer film.

11. The method of claim 9, wherein, Forming the hard coating involves diffusing the coating solution from the top surface of the polymer film to the bottom surface of the printed layer.

12. The method according to claim 9, wherein, The coating solution includes at least one of methanol, isopropanol, isopropyl ether, acetone, methyl ethyl ketone, and propylene glycol methyl ether acetate.

13. A display device, including: Display panel; as well as A cover window is disposed on the display panel, wherein the cover window is a cover window according to any one of claims 1 to 8.

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