Display device

Abstract

The display device includes a display module having a display surface configured to display an image and a window member disposed on the display surface. The window member includes a flexible base layer and a plurality of hard coating patterns, the flexible base layer having a plurality of concave patterns defined on an upper portion thereof, and the plurality of hard coating patterns are each disposed in a corresponding concave pattern among the concave patterns and have a hardness greater than that of the flexible base layer.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This patent application claims priority to and the benefit of Korean Patent Application No. 10-2016-0155978, filed on November 22, 2016, which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present disclosure herein relates to a method for manufacturing a window member and a display device, and, for example, to a method for manufacturing a window member and a display device having both flexibility and improved scratch resistance. Background Art

[0004] Generally, in a display device, glass is used as a window member for protecting a display panel. In addition, tempered glass is used as a window member for protecting the surface of a display device such as a mobile terminal such as a smart phone, a desktop personal computer (PC), etc. However, there are disadvantages in that glass and tempered glass may be damaged by external impact, and it is difficult to apply glass and tempered glass to a flexible display. Therefore, research on realizing a window member using a plastic material has been in steady progress.

[0005] Plastics have been applied as a substitute material for glass due to their light weight, shock resistance, transparency, etc. There is a growing trend to form window members using plastic materials that excel in properties such as weather resistance, scratch resistance against scratches caused by external stimuli, impact resistance to external impacts, and processability. Window members made of plastic can make display devices thin and improve the flexibility of display devices, enabling the realization of flexible displays. Summary of the invention

[0006] Embodiments of the present disclosure provide a display device having improved scratch resistance while maintaining its flexibility.

[0007] Embodiments of the present disclosure also provide a window member included in a display device having improved flexibility and scratch resistance.

[0008] The embodiment of the present disclosure provides a display device, the display device includes a display module and a window member, the display module has a display surface configured to display an image, and the window member is arranged on the display surface. The window member includes a flexible base layer and a plurality of hard coating patterns, wherein the flexible base layer has a plurality of concave patterns defined on an upper portion thereof, and the plurality of hard coating patterns are each arranged in a corresponding concave pattern in the concave patterns and have a hardness greater than that of the flexible base layer.

[0009] In an embodiment, each of the concave patterns may have a set (eg, predetermined) depth in a thickness direction of the flexible base layer, and each of the hard coating patterns may have a height that is the same (eg, substantially the same) as the depth of each corresponding concave pattern.

[0010] In an implementation, each of the hard coating patterns may fill a corresponding space defined by a corresponding one of the concave patterns.

[0011] In embodiments, the flexible base layer and the hard coating pattern may define an upper surface of the window member, wherein the upper surface may be a substantially flat plane.

[0012] In an embodiment, the upper surface may be divided into a first area and a second area adjacent to the first area, the window member is bent or unfolded in the first area, and when viewed on a plane, a portion of the first area on which a hard coating pattern is defined may be smaller than a portion of the second area on which a hard coating pattern is defined.

[0013] In an embodiment, the display module may be bent or unfolded about a bending axis extending in one direction, and each of the plurality of hard coating patterns may extend in a direction parallel to (eg, substantially parallel to) the bending axis.

[0014] In an embodiment, the display module can be bent or unfolded along a first bending axis extending in one direction, and can be bent or unfolded along a second bending axis extending in a direction intersecting the one direction. A plurality of hard coating patterns can be arranged in a matrix form spaced apart in directions parallel to (e.g., substantially parallel to) the first bending axis and the second bending axis, respectively.

[0015] In an implementation, each of the plurality of hard coating patterns may have a semicircular shape, a triangular shape, or a rectangular shape when viewed in cross-section.

[0016] In an implementation, a difference in refractive index between the flexible base layer and the hard coating pattern may be 0 to about 0.2.

[0017] In an embodiment, the flexible base layer may include polyurethane or polycarbonate, and the hard coating pattern may include an acrylate-based compound or an epoxy-based compound.

[0018] In an embodiment of the present disclosure, a method of manufacturing a window member includes: preparing a flexible base layer; forming a plurality of concave patterns on an upper portion of the flexible base layer; and forming a plurality of hard coating patterns in corresponding ones of the concave patterns.

[0019] In an embodiment, forming the concave pattern may be performed by an etching process.

[0020] In an implementation, forming the hard coating pattern may include filling each of the concave patterns with a hard coating material and curing the hard coating material.

[0021] In an embodiment, when a concave pattern is formed, a plurality of first functional groups may be formed on the surface of the concave pattern, and when filled with a hard coating material, a second functional group included in the hard coating material may be chemically bonded to the first functional group (e.g., may chemically react with the first functional group to form a chemical bond).

[0022] In an embodiment, the first functional group and the second functional group may be at least one selected from a hydroxyl group (—OH), a carboxyl group (—COOH), or an isocyanate group (—NCO).

[0023] In an embodiment of the present disclosure, a method for manufacturing a window member includes: forming a plurality of hard coating patterns on a carrier substrate; forming a flexible base layer to completely (eg, substantially completely) cover the hard coating patterns; and removing the carrier substrate.

[0024] In an implementation, forming the hard coating pattern may include: applying a hard coating material such that the hard coating pattern extends in one direction and is spaced apart in a direction crossing the one direction; and curing the hard coating material.

[0025] In an embodiment, forming the flexible base layer may include: applying a base material to cover the hard coating patterns and fill spaces spaced apart between the hard coating patterns; and curing the base material.

[0026] In an embodiment, when the base material is applied, a first functional group included in the surface of the hard coating pattern and a second functional group included in the base material may be chemically bonded (eg, the second functional group may chemically react with the first functional group to form a chemical bond).

[0027] In an embodiment, the first functional group and the second functional group may be at least one selected from a hydroxyl group (—OH), a carboxyl group (—COOH), or an isocyanate group (—NCO). BRIEF DESCRIPTION OF THE DRAWINGS

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

[0029] Figure 1A is a perspective view of a display device according to an embodiment of the present disclosure;

[0030] Figure 1B to Figure 1C is shown in a folded state, Figure 1AA perspective view of the display device shown in ;

[0031] Figure 2A is a combined stereogram of a display device according to an embodiment of the present disclosure;

[0032] Figure 2B is an exploded perspective view of a display device according to an embodiment of the present disclosure;

[0033] Figure 3A is a perspective view of a window member according to an embodiment of the present disclosure;

[0034] Figure 3B is shown in a folded state, Figure 3A A perspective view of the window member shown in ;

[0035] Figure 4A is a cross-sectional view of a window member according to an embodiment of the present disclosure;

[0036] FIG. 4B to FIG. 4C is a plan view of a window member according to an embodiment of the present disclosure;

[0037] Figure 5A is a perspective view of a window member according to an embodiment of the present disclosure;

[0038] FIG. 5B to FIG. 5C is a diagram showing a state in which the Figure 5A A perspective view of the window member shown in ;

[0039] FIG. 6A to FIG. 6C is a plan view of a window member according to an embodiment of the present disclosure;

[0040] Fig. 7A yes Figure 4A An enlarged cross-sectional view of the AA portion;

[0041] Figure 7B yes Fig. 7A An exploded sectional view of the configuration shown in ;

[0042] FIG. 8A to FIG. 8B is a cross-sectional view of a window member according to an embodiment of the present disclosure;

[0043] Fig. 9 is a flowchart showing a method for manufacturing a window member according to an embodiment of the present disclosure;

[0044] FIG. 10A to FIG. 10E are cross-sectional views sequentially illustrating a method for manufacturing a window member according to an embodiment of the present disclosure;

[0045] Fig.11 is a flowchart showing a method for manufacturing a window member according to an embodiment of the present disclosure; and

[0046] FIG. 12A to FIG. 12E are cross-sectional views sequentially illustrating a method of manufacturing a window member according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0047] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. However, the subject matter of the present disclosure may be embodied in different forms and should not be construed as being limited to the embodiments set forth herein. On the contrary, providing these embodiments will make the present disclosure comprehensive and complete, and will fully convey the scope of the subject matter of the present disclosure to those skilled in the art.

[0048] In the present disclosure, when an element (or region, layer, portion, etc.) is referred to as being “on,” “connected to” or “coupled to” another element, the element (or region, layer, portion, etc.) may be directly on, directly connected to or directly coupled to the other element, or intervening elements or layers may be present.

[0049] The same reference numerals refer to the same elements. In addition, in the drawings, the thickness, proportion and size of the elements may be exaggerated for the purpose of clarity and illustration. The term "and / or" includes any and all combinations of one or more of the listed items.

[0050] It will be understood that although the terms first, second, etc. can be used in this article to describe each element, these elements should not be limited to these terms. These terms are used to distinguish one element from another element. For example, without departing from the scope of the exemplary embodiments of the present disclosure, the first element can be called the second element, and similarly, the second element can be called the first element. Unless otherwise clearly indicated in the context, the term in the singular form can include the plural form.

[0051] Additionally, herein, terms such as "below," "lower," "above," "upper," etc. may be used for illustrative purposes and thereby describe the relationship of one element or feature to another element or feature as shown in the drawings. Spatially relative terms are intended to encompass different orientations of the device in use, operation, and / or manufacture in addition to the orientation shown in the drawings.

[0052] It should be understood that when used in this specification, the terms “including” or “having” indicate the existence of the described features, integers, steps, operations, elements, parts and / or combinations thereof, but do not exclude the existence or addition of one or more other features, integers, steps, operations, elements, parts and / or combinations thereof.

[0053] Hereinafter, a display device according to an embodiment of the present disclosure will be described.

[0054] Figure 1A is a perspective view of a display device according to an embodiment of the present disclosure. Figure 1B to Figure 1C They are respectively shown in the folded state, Figure 1A In the following, reference will be made to the display device shown in Figures 1A to 1C A display device DD according to an embodiment of the present disclosure will be described.

[0055] Reference Figure 1A , the display surface IS on which the image IM is displayed is parallel to (e.g., approximately parallel to) the surface defined by the first direction DR1 and the second direction DR2. The normal direction of the display surface IS (i.e., the thickness direction of the display device DD) is represented by a third direction DR3. The front surface (or upper surface) and the rear surface (or lower surface) of each member are distinguished by the third direction DR3. However, the directions indicated by the first direction DR1 to the third direction DR3 are relative concepts and can be changed to different directions. In the following, the first direction to the third direction are the directions indicated by the first direction DR1 to the third direction DR3, respectively, and are assigned the same or approximately the same figure marks. In the present embodiment, a flexible display device is shown, but the subject matter of the present disclosure is not limited thereto.

[0056] Reference Figure 1A , the display surface IS of the display device DD according to the embodiment of the present disclosure may include a plurality of regions. The display device DD includes a display region DD-DA on which an image IM is displayed and a non-display region DD-NDA adjacent to the display region DD-DA. The non-display region DD-NDA is a region on which no image is displayed. Figure 1A , an application icon and a clock window are shown as examples of the image IM. The display area DD-DA may be in a square shape. The non-display area DD-NDA may surround the display area DD-DA, but is not limited thereto. The shape of the display area DD-DA and the shape of the non-display area DD-NDA may be designed relative to each other.

[0057] The display device DD may include a housing. The housing is provided on the outside of the display device DD and may accommodate components inside.

[0058] Reference Figure 1B , the display device DD according to the embodiment of the present disclosure can be folded inwardly relative to the bending axis BX. Figure 1C , the display device DD according to the embodiment of the present disclosure can be folded outward relative to the reference of the bending axis BX. Figure 1B to Figure 1C The folding method of the display device DD is exemplarily shown in FIG. 1 , but is not limited thereto.

[0059] The display device DD according to the embodiment of the present disclosure may be a foldable display device or a rollable display device that can be rolled up, but is not limited thereto. The display device DD according to the embodiment of the present disclosure may be a stretchable display device. The display device DD according to the embodiment of the present disclosure may be used in large electronic devices such as televisions, display screens, etc., or may be used in small and medium-sized electronic devices such as mobile phones, tablet computers, global positioning systems (GPS), game consoles, smart watches, etc.

[0060] Figure 2A is a combined stereogram of a display device according to an embodiment of the present disclosure. Figure 2B is an exploded perspective view of a display device according to an embodiment of the present disclosure. FIG. 2A to FIG. 2B In the Figure 1A Components of the display device shown in .

[0061] Reference FIG. 2A to FIG. 2B , the display device DD according to an embodiment of the present disclosure includes a window member WM and a display module DM. The display module DM may include a protective film PM, a display panel DP, and a touch sensing unit TS.

[0062] The display device DD may further include a first adhesive member and a second adhesive member. The first adhesive member may combine the display panel DP and the protection film PM, and the second adhesive member may combine the display module DM and the window member WM.

[0063] The first and second adhesive members may be optically clear adhesive films (OCA), optically clear resins (OCR), or pressure sensitive adhesive films (PSA). The first and second adhesive members may include photocurable adhesive materials or thermally curable adhesive materials, but the materials thereof are not particularly limited.

[0064] The protective film PM and the window member WM may both be continuously formed by a coating process. The protective film PM protects the display module DM. The protective film PM prevents moisture from the outside from penetrating the display module DM (or reduces the possibility or degree of such moisture penetration) and absorbs external impact.

[0065] The protective film PM may include a plastic film as a base member. The protective film may include a plastic film having one selected from the group consisting of polyethersulfone (PES), polyacrylate, polyetherimide (PEI), polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polyphenylene sulfide (PPS), polyarylate, polyimide (PI), polycarbonate (PC), poly (arylethersulfone) and combinations thereof. As used herein, the terms "combinations thereof" and "combinations thereof" may refer to chemical combinations (e.g., alloys or compounds), mixtures or laminated structures of components.

[0066] The material constituting the protective film PM is not limited to the plastic resin and may include an organic / inorganic compound material. The protective film PM may include a porous organic layer and an inorganic material filling the pores of the organic layer. The protective film PM may also include a film function layer formed on a plastic film. The film function layer may include a resin layer. The film function layer may be formed by a coating method.

[0067] The window member WM is disposed on the display module DM and covers the display module DM. The window member WM may protect the display module DM from external impact and may provide an input surface for the user. A detailed description of the window member WM will be described later.

[0068] The display panel DP and the touch sensing unit TS may be formed integrally with each other through a continuous process, but are not limited thereto. The touch sensing unit TS may be bonded to the display panel DP by a bonding member. The display panel DP generates an image IM (see FIG. 1 ) corresponding to input image data.

[0069] The display device DD may further include a frame structure to hold Figure 1B to Figure 1C The folded state shown in . The frame structure may include a joint structure or a hinge structure.

[0070] Figure 3A is a perspective view of a window member according to an embodiment of the present disclosure. Figure 3B is a perspective view showing a window member according to an embodiment of the present disclosure in a folded state. FIG. 3A to FIG. 3B A window member WM according to an embodiment of the present disclosure will be described.

[0071] Reference FIG. 3A to FIG. 3B , the window member WM according to an embodiment of the present disclosure includes a flexible base layer BS and a plurality of hard coating patterns HCP.

[0072] The flexible base BS may be formed of a polymer material. For example, the flexible base BS may be made of the following materials: polyimide, polyacrylate, polymethyl methacrylate (PMMA), polycarbonate (PC), polyethylene naphthalate (PEN), polyvinylidene chloride, polyvinylidene fluoride (PVDF), polystyrene, ethylene vinyl alcohol copolymer or a combination thereof. However, the material of the flexible base BS used in the embodiment is not limited to the listed polymer materials. As long as the material has optical transparency that provides the image provided by the display module of the display device to the user, any suitable material may be used without limitation. For example, the window member WM of the embodiment may use polyurethane (PU) as the flexible base BS. The flexible base BS made of PU may have excellent transparency and may have high strength and high surface hardness.

[0073] On the upper surface of the flexible base layer BS, a plurality of concave patterns are defined. The plurality of hard coating patterns HCP are each disposed in a corresponding concave pattern among the plurality of concave patterns defined on the upper surface of the flexible base layer BS.

[0074] A plurality of hard coating patterns HCP have a hardness greater than that of the flexible base layer BS. A plurality of hard coating patterns HCP may include a material having a greater rigidity than that of the flexible base layer BS. The hard coating pattern HCP may be an organic pattern or an organic / inorganic hybrid pattern. When the hard coating pattern HCP is an organic pattern, the hard coating pattern HCP may include an acrylate-based compound. For example, the hard coating pattern HCP may include urethane acrylate. Alternatively, the hard coating pattern HCP may include an epoxy-based compound.

[0075] When the hard coating pattern HCP is an organic / inorganic hybrid pattern, the hard coating pattern HCP may be a mixture of an organic substance and inorganic particles. In this case, the organic substance may include an acrylate-based compound, and the inorganic particles may include an inorganic oxide. The inorganic oxide included in the inorganic particles may be one selected from the group consisting of silicon oxide (SiO 2 ), zirconium oxide (ZrO 2 ), aluminum oxide (Al 2 O 3 ), Tantalum Oxide (Ta 2 O 5 ), niobium oxide (Nb 2 O 5 、NbO 2 ), glass beads and combinations thereof.

[0076] The difference in refractive index between the hard coating pattern HCP and the flexible base layer BS may be 0 to about 0.2. The refractive index of the hard coating pattern HCP may be 0 to about 0.2 less than the refractive index of the flexible base layer BS, or 0 to about 0.1 greater. The refractive index of the flexible base layer BS may be about 1.49 to about 1.50, and the refractive index of the hard coating pattern HCP may be about 1.30 to about 1.60. If the refractive index of the hard coating pattern HCP satisfies the above range, blur or chaos can be prevented from occurring at the window member WM (or the possibility or degree of such blur or chaos can be reduced), and the transparency of the window member WM can be prevented from being reduced due to the hard coating pattern HCP (or the possibility or degree of such reduced transparency can be reduced).

[0077] Each of the plurality of hard coating patterns HCP may be spaced apart from an adjacent one of the hard coating patterns HCP along the first direction DR1 and extend along the second direction DR2, but is not limited thereto. Each of the plurality of hard coating patterns HCP may be spaced apart from an adjacent one of the hard coating patterns HCP along the second direction DR2 and extend along the first direction DR1.

[0078] The window member WM may be bent or unfolded around the bending axis BX. The state in which the window member WM is bent around the bending axis BX may correspond to Figure 3B The state shown in the figure, and the state of the window component WM expansion may correspond to Figure 3A The status shown in .

[0079] The bending axis BX may extend along the second direction DR2. Therefore, each of the plurality of hard coating patterns HCP may extend in a direction parallel to (e.g., substantially parallel to) the bending axis BX. Each of the plurality of hard coating patterns HCP may extend in a direction parallel to (e.g., substantially parallel to) the bending axis BX, and be spaced apart from an adjacent one of the hard coating patterns HCP in a direction intersecting the bending axis BX.

[0080] According to the window member of the embodiment of the present disclosure, there is no hard coating layer formed on the front surface of the flexible base, but there are multiple hard coating patterns that are patterned. Therefore, it is possible to prevent the hard coating layer from being damaged or deformed (or reduce the possibility or degree of such damage or deformation) when the window member is folded when the hard coating layer is formed on the front surface of the flexible base. In particular, according to the window member of the embodiment of the present disclosure, there may be multiple hard coating patterns extending in a direction parallel to (for example, approximately parallel to) the bending axis. Therefore, the stress generated when the window member is folded along the bending axis is not applied in the direction in which multiple hard coating patterns extend, and therefore, it is possible to prevent the hard coating layer from being damaged or deformed (or reduce the possibility or degree of such damage or deformation).

[0081] Figure 4A is a cross-sectional view of a window member according to an embodiment of the present disclosure. Figure 4B is a plan view of a window member according to an embodiment of the present disclosure. Figure 3A , Figure 4A and Figure 4B A window member according to an embodiment of the present disclosure is described.

[0082] Reference Figure 3A and Figure 4A The upper surface of the window member WM may be defined by the flexible base layer BS and the hard coating pattern HCP. The upper surface of the window member WM may be defined by the upper surface of the flexible base layer BS provided with the concave pattern and the upper surface of the flexible base layer BS having no concave pattern thereon.

[0083] The upper surface of the window member WM may be a substantially flat plane. The upper surface of the window member WM may be flat without protrusions. The upper surface of the hard coating pattern HCP on which the concave pattern is disposed may be coupled to (e.g., connected to) the upper surface of the flexible base layer BS on which there is no concave pattern, and may define a substantially flat plane.

[0084] According to the window member of the embodiment of the present disclosure, there are multiple hard coating patterns arranged on the upper part of the flexible base without a step portion. For example, multiple hard coating patterns fill multiple concave patterns defined on the upper part of the flexible base, so that the upper surface of the window member presents a shape without a step portion. Therefore, since the upper surface of the window member forms a flat plane and the hard coating pattern does not protrude to the outside, it is possible to prevent the hard coating pattern from detaching from the window member when the window member is folded or curled (or reduce the possibility or degree of such detachment), and when the surface is scratched by an external object, the problem of the protruding hard coating pattern detaching or being damaged does not occur. In addition, it is possible to prevent blurring (or reducing the possibility or degree of such blurring) on ​​the display device due to the step portion when the hard coating pattern protrudes.

[0085] Reference Figure 4B , the upper surface of the window member WM may be divided into a base area A1 defined by the flexible base layer BS and a pattern area A2 defined by a plurality of hard coating patterns HCP. In the window member WM according to an embodiment of the present disclosure, the pattern area A2 may extend along the second direction DR2 and be spaced apart from adjacent pattern areas A2 along the first direction DR1.

[0086] The pattern area A2 may occupy about 70% to about 90% of the entire area of ​​the upper surface of the window member WM. If the area occupied by the pattern area A2 satisfies the above range, the window member WM may have flexibility and sufficient resistance to scratches caused by external impacts.

[0087] Figure 4C is a plan view of a window member according to an embodiment of the present disclosure.

[0088] Reference Figure 4C , the upper surface of the window member WM′ may be divided into a first area BA where the window member WM′ is bent or unfolded and a second area NBA adjacent to the first area BA. The second area NBA may be a flat area where the window member WM′ is not bent. Figure 4C , one first area BA and the second areas NBA disposed on the respective sides of the first area BA are exemplarily shown, but are not limited thereto. A plurality of first areas BA may be disposed on the upper surface of the window member WM'.

[0089] On the upper surface of the window member WM' according to an embodiment of the present disclosure, the proportion of the pattern area A2 on which the hard coating pattern is disposed may be differently defined relative to the first area BA and the second area NBA. For example, the proportion of the pattern area A2 defined in the first area BA may be smaller than the proportion of the pattern area A2 defined in the second area NBA. Along the first direction DR1 on the plane, the plurality of first hard coating patterns HCP-BA disposed in the first area BA may have a narrower width than the plurality of second hard coating patterns HCP-NBA.

[0090] According to the window member of the embodiment of the present disclosure, the proportion of the hard coating pattern provided in the folding area can be smaller than the proportion of the hard coating pattern provided in the non-folding area. Therefore, the flexibility of the window member in the folding area can be improved, and a larger proportion of the hard coating pattern is provided in the non-folding area, so that the hardness of the window member can be improved and its scratch resistance can be improved.

[0091] Figure 5A is a perspective view of a window member according to another embodiment of the present disclosure in an open state. Figure 5B is a diagram showing a state in which the Figure 5A A perspective view of the window member shown in FIG. Figure 5C is a diagram showing a state in which the Figure 5A In the following, reference will be made to the window member shown in FIG. FIG. 5A to FIG. 5C The window member WM-1 according to the embodiment of the present disclosure is described. FIG. 3A to FIG. 3B The same or substantially the same configurations as those described in are assigned the same or substantially the same reference numerals, and therefore, description thereof need not be repeated here.

[0092] The window member WM-1 includes a flexible base layer BS-1, and a plurality of hard coating patterns HCP-1 may be arranged in a matrix form spaced apart along a first direction DR1 and a second direction DR2, respectively. The plurality of hard coating patterns HCP-1 may include pattern rows spaced apart along the first direction DR1, and pattern lines spaced apart along the second direction DR2. FIG. 5A to FIG. 5B , the patterns are exemplarily depicted as being equally spaced apart along the first direction DR1 and the second direction DR2, but are not limited thereto. The intervals spaced apart along the first direction DR1 and the intervals spaced apart along the second direction DR2 may be different from each other.

[0093] The window member WM-1 may be bent or unfolded around a first bending axis BX1. The first bending axis BX1 may extend along a second direction DR2. The window member WM-1 may be bent or unfolded around a second bending axis BX2. The second bending axis BX2 may extend along the first direction DR1. A plurality of hard coating patterns HCP-1 may be arranged in a matrix form spaced apart in a direction parallel to (e.g., substantially parallel to) the first bending axis BX1 and spaced apart in a direction parallel to the second bending axis BX2.

[0094] According to the embodiment of the present disclosure, the window member can be folded along multiple axes. For example, the window member can be folded along two axes that intersect each other. According to the embodiment of the present disclosure, the window member has a plurality of hard coating patterns arranged in a matrix form, so that even when the window member is folded along any one of the two bending axes, stress is not applied in the direction in which the hard coating pattern extends, and thus, the hard coating layer can be prevented from being damaged or deformed (or the possibility or degree of such damage or deformation is reduced).

[0095] Fig. 6A is a plan view of a window member according to an embodiment of the present disclosure. Figure 6B is a plan view of a window member according to another embodiment of the present disclosure. Figure 6C is a plan view of a window member according to another embodiment of the present disclosure. Figure 4B The same or substantially the same configurations as those described in are assigned the same or substantially the same reference numerals, and therefore, description thereof need not be repeated here.

[0096] The plurality of hard coating patterns HCP-1 may be arranged in a matrix form spaced apart along the first direction DR1 and the second direction DR2, respectively. Fig. 6A As shown, each of the plurality of hard coating patterns HCP-1 may have a rectangular shape in plane. Alternatively, as Figure 6B As shown, in the window member WM-2 including the flexible base layer BS-2, each of the plurality of hard coating patterns HCP-2 may have a circular shape in a plane. Figure 6C As shown, in the window member WM-3 including the flexible base layer BS-3, each of the plurality of hard coating patterns HCP-3 may be randomly arranged without regularity. FIG. 6B to FIG. 6C When configured as shown, the display device may be a stretchable display device.

[0097] Fig. 7A yes Figure 4A An enlarged cross-sectional view of the AA portion. Figure 7B yes Fig. 7A In the following, reference will be made to FIG. 7A to FIG. 7BArrangements of the flexible base layer BS and the hard coating pattern HCP in the window member WM according to an embodiment of the present disclosure are explained.

[0098] Each of the hard coating patterns HCP is disposed in a corresponding concave pattern among a plurality of concave patterns CP defined in an upper portion of the flexible base layer BS. Each of the hard coating patterns HCP is disposed in a corresponding concave pattern among the concave patterns CP corresponding to the hard coating pattern HCP. Each of the hard coating patterns HCP may fill a corresponding space defined by the concave pattern CP. Each of the plurality of hard coating patterns HCP may have the same (e.g., substantially the same) shape as the space defined by the concave pattern CP.

[0099] The thickness d2 of each of the hard coating patterns HCP may be the same or substantially the same as the thickness d1 of each of the concave patterns CP. For example, the thickness d2 of each of the hard coating patterns HCP and / or the thickness d1 of each of the concave patterns CP may be about 5 μm to about 20 μm. If the thickness of the hard coating pattern HCP satisfies the above range, the window member may have sufficient scratch resistance and flexibility capable of folding or curling the window member.

[0100] Each of the hard coating patterns HCP may include a bottom surface HCP-S corresponding to the inner surface CP-S defining the inner space of the concave pattern CP, respectively. The bottom surface HCP-S of each of the hard coating patterns HCP may have a shape roughly corresponding to the inner surface CP-S of the concave pattern CP. Since the bottom surface HCP-S of the hard coating pattern HCP roughly corresponds to the inner surface CP-S of the concave pattern CP, each of the hard coating patterns HCP completely fills the concave pattern CP and may not protrude to the outside of the upper surface of the window member.

[0101] Fig. 8A is a cross-sectional view of a window member according to another embodiment of the present disclosure. Figure 8B is a cross-sectional view of a window member according to another embodiment of the present disclosure. FIG. 8A to FIG. 8B Shown compared to Figure 4A The window members shown in FIG. have window members with hard coating patterns of different shapes. Figure 4A , Fig. 8A and Figure 8B The window member according to the embodiment of the present disclosure is described. Figure 4A The same or substantially the same configurations as those described in are assigned the same or substantially the same reference numerals, and therefore, description thereof need not be repeated here.

[0102] When viewed in cross section, the hard coating pattern according to the embodiment of the present disclosure may have various suitable shapes. Figure 4A As shown, the hard coating pattern HCP may have a semicircular shape when viewed in cross section. Fig. 8A As shown in the window member WM-4 including the flexible base layer BS-4, the hard coating pattern HCP-4 may have a pyramidal triangular shape when viewed in cross section. Figure 8B As shown in the window member WM-5 including the flexible base BS-5, when viewed in cross section, the hard coating pattern HCP-5 may be rectangular in shape, but the present disclosure is not limited thereto. The hard coating pattern may be provided in various suitable shapes that are the same or substantially the same as the shape of the concave pattern defined on the upper surface of the flexible base.

[0103] A method of manufacturing a display device according to an embodiment of the present disclosure includes the steps of: preparing a display module including a display surface configured to display an image; providing a window member; and bonding the window member to the display surface.

[0104] Hereinafter, a method of manufacturing a window member included in a display device according to an embodiment of the present disclosure will be described.

[0105] Fig. 9 is a flowchart illustrating a method of manufacturing a window member according to an embodiment of the present disclosure. FIG. 10A to FIG. 10E are cross-sectional views sequentially illustrating a method of manufacturing a window member according to an embodiment of the present disclosure.

[0106] like Fig. 9 As shown, the manufacturing method of the window member according to the embodiment of the present disclosure includes the following steps: a step S100 of preparing a flexible base layer; a step S200 of forming a plurality of concave patterns on the flexible base layer; and a step S300 of forming a plurality of hard coating patterns in corresponding concave patterns in the concave patterns. The step S300 of forming the plurality of hard coating patterns may include a step S310 of filling each of the concave patterns with a hard coating material and a step S320 of curing the hard coating material.

[0107] Reference Fig. 9 and Fig. 10A , a flexible base layer BS′ is prepared, and a mask MS may be disposed on the flexible base layer BS′. Since a plurality of openings are defined in the mask MS, at least a portion of an upper surface of the flexible base layer BS′ may be exposed.

[0108] Reference Fig. 9 and Fig. 10B The method for manufacturing a window member according to an embodiment of the present disclosure includes a step S200 of forming a plurality of concave patterns on a flexible base layer BS' on which a mask MS is disposed. The step S200 of forming the plurality of concave patterns may be performed using an etching process. The plurality of concave patterns may be formed by a dry etching method such as plasma etching, ion beam etching, laser etching, etc., or by a method such as Fig. 10BThe plurality of concave patterns may be formed by a wet etching method in which an etching solution Et is supplied from a plurality of nozzles NZ1. 2 ) plasma etching or nitrogen oxide (N 2 O) plasma etching formation.

[0109] Reference FIG. 10B to FIG. 10C , a plurality of concave patterns CP are formed on the upper portion of the flexible base layer BS by an etching process or the like. The region of the upper surface of the flexible base layer BS where the mask MS is disposed before the etching step is not etched because the plasma or the like cannot reach it. A plurality of concave patterns CP are formed by an etching process on the upper surface of the flexible base layer BS exposed by the plurality of openings defined by the mask MS. Fig. 10C In the example, it is shown that Figure 4A The concave pattern CP is shown as having a semicircular shape when viewed in cross section, but is not limited thereto. The concave pattern CP may be formed to have various appropriate shapes. In the step of forming the concave pattern, a random concave pattern may be formed by setting a random mask before the etching step.

[0110] On each surface of the concave pattern CP of the flexible base layer BS', a plurality of first functional groups may be formed by an etching process. The plurality of first functional groups may be formed as chemical bonds in the polymer included in the flexible base layer BS' are destroyed by oxygen plasma or the like. The plurality of first functional groups may be at least one selected from a hydroxyl group (-OH), a carboxyl group (-COOH), or an isocyanate group (-NCO).

[0111] Reference Fig. 9 and Fig. 10D , the hard coating material CM can be used as Fig. 10D The plurality of nozzles NZ2 shown in FIG. 1 are filled into each of the concave patterns formed on the flexible base layer BS. The hard coating material CM may be provided in a liquid form and fill the space defined by each of the concave patterns. The hard coating material CM may be provided by screen printing, inkjet printing, spraying or a roll-to-roll process.

[0112] A second functional group may be included in the hard coating material CM. The second functional group may be at least one selected from a hydroxyl group (-OH), a carboxyl group (-COOH) and an isocyanate group (-NCO). The second functional group may react with the first functional group and may be chemically bonded to the first functional group (e.g., the second functional group may react with the first functional group to form a chemical bond). Since the second functional group included in the hard coating material CM is chemically bonded to the first functional group formed on the surface of the concave pattern, the plurality of hard coating patterns in the window member according to the embodiment of the present disclosure may not be easy to break away from the concave pattern. In this case, the first functional group and the second functional group may be bonded by a urethane bond (e.g., the first functional group and the second functional group may chemically react to form a urethane bond).

[0113] Then, if Fig.10E As shown in , a plurality of hard coating patterns HCP are formed on the upper part of the flexible base BS by curing the hard coating material filled in a plurality of concave patterns. A plurality of hard coating patterns HCP are formed by filling the hard coating material into a shape corresponding to a plurality of concave patterns and curing the filled hard coating material. Therefore, a step portion may not be formed on the upper surface of the window member WM. Accordingly, since the upper surface of the window member forms a substantially flat plane and the hard coating pattern does not protrude to the outside, the hard coating pattern is not easily detached when the window member is folded or curled, and when scratched by an external object, the protruding hard coating pattern does not detach or be damaged. In addition, it is possible to prevent blurring in the display device due to the step portion when the hard coating pattern protrudes (or reduce the possibility or degree of such blurring).

[0114] Fig.11 is a flowchart illustrating a method of manufacturing a window member according to another embodiment of the present disclosure. FIG. 12A to FIG. 12E are cross-sectional views sequentially illustrating a method of manufacturing a window member according to another embodiment of the present disclosure.

[0115] like Fig.11 As shown, the manufacturing method of the window member according to the embodiment of the present disclosure may include the following steps: a step S100′ of forming a plurality of hard coating patterns on a carrier substrate; a step S200′ of forming a flexible base layer to completely (e.g., substantially completely) cover the hard coating patterns; and a step S300′ of removing the carrier substrate. The step S100′ of forming the hard coating patterns may include a step S110′ of applying a hard coating material to extend in one direction and to be spaced apart in a direction intersecting the one direction; and a step S120′ of curing the hard coating material. The step S200′ of forming the flexible base layer may include a step S210′ of applying a base material to cover the hard coating patterns and to fill the spaces spaced apart between the hard coating patterns; and a step S220′ of curing the base material.

[0116] Reference Fig.11 and Fig. 12A , a carrier substrate CS was prepared, and the Fig. 12A The nozzle NZ3 shown in FIG. 2 applies the hard coating material CM on the carrier substrate CS. The hard coating material CM may be applied to extend along one direction and to be spaced apart in a direction intersecting the one direction. For example, the hard coating material CM may be patterned and applied to extend in a second direction DR2 (see FIG. 2 ). Figure 4B ) and extends in the first direction DR1 (see FIG. Figure 4B ) are spaced apart from each other on the carrier substrate CS, but are not limited thereto. The hard coating material CM may be applied to be arranged in a matrix form on the carrier substrate CS, or applied randomly without a regular pattern.

[0117] Reference Fig.11 and Fig. 12B , a plurality of hard coating patterns HCP may be formed by curing the applied hard coating material. The plurality of hard coating patterns HCP may be formed to be spaced apart at a set (eg, predetermined) interval on the carrier substrate CS. Between each of the plurality of hard coating patterns HCP, a separation space SP may be defined.

[0118] On the surface of the plurality of hard coating patterns HCP, a first functional group may be included. For example, on the surface of the plurality of hard coating patterns HCP, the first functional group may be exposed to the outside. The first functional group may be at least one selected from a hydroxyl group (-OH), a carboxyl group (-COOH) or an isocyanate group (-NCO).

[0119] Reference Fig.11 and Fig. 12C , the base material BM is applied to cover the plurality of hard coating patterns HCP. The base material BM may be applied to fill the separation spaces SP between the hard coating patterns HCP. Therefore, in the separation spaces SP between the hard coating patterns HCP, the surface of the carrier substrate CS is not exposed to the outside.

[0120] A second functional group may be included in the base material BM. At least one of the materials included in the base material BM may be a material including a second functional group. The second functional group may be at least one selected from a hydroxyl group (-OH), a carboxyl group (-COOH) or an isocyanate group (-NCO). When the base material BM is applied to cover the hard coating pattern HCP, the first functional group and the second functional group may be chemically combined so that the plurality of hard coating patterns HCP may not be easily separated from the base material BM. In this case, the first functional group and the second functional group may be combined by a urethane bond (e.g., the first functional group and the second functional group may react to form a urethane bond).

[0121] Reference Fig.11 , Fig.12Dand Fig.12E , a flexible base layer BS is formed by curing the applied base material BM. Fig.12D In the embodiment, the base material BM is cured by light L from a plurality of lamps LM, but the present disclosure is not limited thereto. The base material BM may be cured by various appropriate methods. After the flexible base layer BS is formed by curing the base material BM, the carrier substrate CS is removed and the window member WM is finally formed.

[0122] The window member according to the embodiment of the present disclosure can be formed by the following steps: first, a hard coating pattern is formed on a carrier substrate; and then a flexible base layer is formed to cover the hard coating pattern, so that no step portion is formed on the surface formed with the hard coating pattern and one surface of the window member is formed as a flat plane. The window member according to the embodiment of the present disclosure has a hard coating pattern that does not protrude to the outside, so that the hard coating pattern is not easily detached when the window member is folded or curled, and when scratched by an external object, the problem of the protruding hard coating pattern being detached or damaged does not occur. In addition, it is possible to prevent blurring due to the step portion when the hard coating pattern protrudes (or reduce the possibility or degree of such blurring).

[0123] The display device according to the embodiment of the present disclosure may have strong resistance to external scratches and at the same time may ensure flexibility when folded or rolled.

[0124] The method of manufacturing a window member according to an embodiment of the present disclosure may provide a display device having strong resistance to external scratches and at the same time having assured flexibility when folded or rolled.

[0125] As used herein, the terms "substantially," "approximately," and similar terms are used as terms of approximation rather than as terms of degree, and are intended to illustrate the inherent deviations of measured or calculated values ​​that are recognized by those of ordinary skill in the art. In addition, "may" is used when describing embodiments of the present disclosure to represent "one or more embodiments of the present disclosure." As used herein, the terms "use," "using," and "used" may be considered synonymous with the terms "utilize," "utilizing," and "utilized," respectively. In addition, the term "exemplary" is intended to represent an example or illustration.

[0126] The subject matter disclosed above should be considered illustrative rather than restrictive, and the appended claims are intended to cover all such modifications, improvements, and other embodiments that fall within the true spirit and scope of the disclosure. Therefore, to the maximum extent allowed by law, the scope of the present disclosure should be determined by the broadest permissible interpretation of the appended claims and their equivalents, and should not be restricted or limited to the above detailed description.

Claims

1. A method for manufacturing a window member, comprising: preparing a flexible base layer; forming a plurality of concave patterns on an upper portion of the flexible base layer; as well as forming a plurality of hard coating patterns in the concave pattern, Wherein, forming the hard coating pattern comprises: filling the concave pattern with a hard coating material, and in: When the concave pattern is formed, a plurality of first functional groups are formed on a surface of the concave pattern; and When filled with the hard coating material, the second functional group present in the hard coating material is chemically bonded to the first functional group.

2. The method of claim 1, wherein: The forming of the concave pattern is performed by an etching process.

3. The method of claim 1, wherein: Forming the hard coating pattern further comprises: The hard coating material is cured.

4. The method of claim 1, wherein: The first functional group and the second functional group are at least one selected from the group consisting of a hydroxyl group (—OH), a carboxyl group (—COOH), and an isocyanate group (—NCO).

5. A method for manufacturing a window member, comprising: forming a plurality of hard coating patterns on a carrier substrate; forming a flexible base layer to completely cover the hard coating pattern; as well as The carrier substrate is removed.

6. The method of claim 5, wherein: Forming the hard coating pattern includes: applying a hard coating material such that the hard coating patterns extend in one direction and are spaced apart in a direction crossing the one direction; and The hard coating material is cured.

7. The method of claim 6, wherein: Forming the flexible base layer comprises: applying a base material to cover the hard coating patterns and fill spaces spaced apart between the hard coating patterns; and The base material is cured.

8. The method of claim 7, wherein: When the base material is applied, the first functional group present at the surface of the hard coating pattern is chemically bonded with the second functional group present in the base material.

9. The method of claim 8, wherein: The first functional group and the second functional group are at least one selected from the group consisting of a hydroxyl group (—OH), a carboxyl group (—COOH), and an isocyanate group (—NCO).

10. A display device comprising: a display module comprising a display surface configured to display an image; as well as A window member, the window member being arranged on the display surface, wherein the window member comprises: a flexible base layer having a plurality of concave patterns defined on an upper portion of the flexible base layer; and a plurality of hard coating patterns, each of the plurality of hard coating patterns being disposed in a corresponding concave pattern among the plurality of concave patterns and having a hardness greater than that of the flexible base layer, in: The flexible base layer includes a first functional group, and the plurality of hard coating patterns each include a second functional group, and The second functional group is chemically bonded to the first functional group, wherein the plurality of hard coating patterns include an acrylate-based compound or an epoxy-based compound, and the flexible base layer includes polyurethane or polycarbonate, and The first functional group and the second functional group are at least one selected from the group consisting of a hydroxyl group (—OH), a carboxyl group (—COOH), and an isocyanate group (—NCO).

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