Display device and method of manufacturing the same

Abstract

The present invention relates to a display device and a method of manufacturing the same. The display device includes a display module, a first support member, and a second support member. Among them, the display module includes a non-folded portion and a folded portion disposed between the non-folded portions; the first support member is disposed under the display module; and the second support member is disposed between the display module and the first support member. Among them, the first support member may include a first support portion and a second support portion that overlap with the non-folded portion and a plurality of support units that overlap with the folded portion.

Description

[0001] This application is a divisional application of the application with the filing date of March 14, 2019, application number 201910192979.X, and invention title "Display Device and Method of Manufacturing the Same".

[0002] Cross-reference to related applications

[0003] This application claims the priority and benefits of Korean Patent Application No. 10-2018-0038593, filed on April 3, 2018. For all purposes, the Korean patent application is incorporated herein by reference as if fully set forth herein. Technical field

[0004] The present disclosure relates to a display device and a method of manufacturing a display device. Background art

[0005] Generally, electronic devices such as smartphones, digital cameras, laptop computers, navigation units, smart TVs, etc. include a display device to display images. The display device generates an image and provides the generated image to a user through a display screen.

[0006] In recent years, with the continuous development of display device technology, various display devices have been developed. For example, curved, foldable, or rollable flexible display devices have been proposed. The flexible display device is easy to carry and improves user convenience. However, in the case of a foldable display device, the folded portion of the display device is damaged or deformed due to the folding operation. Therefore, there is an increasing need to develop a display device capable of preventing or reducing damage and deformation in the folded portion.

[0007] The above information disclosed in this background art section is only for understanding the background art of the inventive concept, and thus, it may include information that does not constitute the prior art. Summary of the invention

[0008] A device constructed according to an exemplary embodiment of the present invention provides a display device capable of preventing damage and deformation of a display module due to a folding operation or capable of reducing damage and deformation in the display module.

[0009] A method according to an exemplary embodiment of the present invention provides a method of manufacturing a display device capable of simplifying a manufacturing process.

[0010] Additional features of the inventive concept will be set forth in the following description, and by the description, the additional features will be somewhat apparent or may be learned by the practice of the inventive concept.

[0011] According to one or more embodiments of the present invention, a display device includes a display module, a first support member, and a second support member. The display module includes a non-foldable portion and a foldable portion disposed between the non-foldable portions. The first support member is disposed under the display module, and the second support member is disposed between the display module and the first support member. The first support member may include a first support portion and a second support portion that overlap the non-foldable portion and a plurality of support units that overlap the foldable portion.

[0012] The first support member may include a metallic material, and the second support member may include an elastic material.

[0013] The first support member may include aluminum or stainless steel, and the second support member may include rubber, silicone, or urethane.

[0014] The display device may further include an adhesive member that attaches the display module to the second support member.

[0015] The second support member may be attached to the first support member.

[0016] The foldable portion and the non-foldable portion may be arranged in a first direction, and the support units may extend in a second direction that intersects the first direction.

[0017] The foldable portion may be configured to rotate about a rotation axis that is substantially parallel to the second direction to fold the display module, and the support units may be spaced apart from each other along the foldable portion, and the display module may be folded inwardly so as not to be exposed to the outside.

[0018] The first support member may have a thickness of from about 0.1 mm to about 0.5 mm in a third direction that is substantially perpendicular to the plane defined by the first direction and the second direction.

[0019] The second support member may have a thickness of from about 0.2 mm to about 0.3 mm in the third direction.

[0020] According to one or more embodiments of the present invention, a method of manufacturing a display device includes: forming a plurality of cutting grooves on a lower surface of a folding region of a first support member, the folding region of the first support member being disposed between non-foldable regions of the first support member; disposing a second support member on the first support member; disposing a display module on the second support member; bending the folding region and a foldable portion of the display module corresponding to the folding region to fold the display module inwardly; and cutting a portion of the folding region corresponding to the cutting grooves by applying stress that occurs in the folding region, wherein the folding region and the non-foldable regions may be arranged in a first direction, the cutting grooves extend in a second direction that intersects the first direction, and the folding region and the foldable portion are configured to rotate about a rotation axis that is substantially parallel to the second direction to be bent.

[0021] Each of the cutting grooves may have a depth in a third direction substantially perpendicular to the plane defined by the first direction and the second direction, which is equal to or greater than half of the thickness of the first support member and less than the thickness of the first support member.

[0022] The first support member may include a metallic material, and the second support member may include an elastic material.

[0023] The method may further include attaching the display module to the second support member using an adhesive member.

[0024] According to one or more embodiments of the present invention, a display device includes a display module, a first support member, a second support member, and an adhesive member, wherein the display module includes a non-folded portion and a folded portion disposed between the non-folded portions, the first support member is disposed under the display module, the first support member includes a first support portion and a second support portion overlapping the non-folded portions of the display module, the second support member is disposed between the non-folded portions and the first and second support portions and between the first support portion and the second support portion, the second support member has a predetermined elasticity, and the adhesive member attaches the display module to the second support member.

[0025] The second support member may include a third support portion, a fourth support portion, and a fifth support portion, wherein the third support portion is disposed between the first support portion and the non-folded portion of the display module overlapping the first support portion, the fourth support portion is disposed between the second support portion and the non-folded portion of the display module overlapping the second support portion, and the fifth support portion is disposed between the first support portion and the second support portion.

[0026] The fifth support portion may include a plurality of protrusions, wherein the folded portion and the non-folded portion may be arranged in a first direction, and wherein the protrusions may extend in a second direction crossing the first direction and protrude downward more than the lower surfaces of each of the first support portion and the second support portion.

[0027] The lower surface of the fifth support portion may be formed flush with the lower surfaces of each of the first support portion and the second support portion.

[0028] The display device may further include a sixth support portion and a seventh support portion, wherein the sixth support portion is disposed under the fifth support portion and the first support portion, and the seventh support portion is disposed under the fifth support portion and the second support portion, and wherein the sixth support portion and the seventh support portion may be spaced apart from each other with respect to the center of the fifth support portion.

[0029] A part of the sixth supporting part may be disposed under a predetermined part of the first supporting part adjacent to the fifth supporting part, and the sixth supporting part is connected to the lower part of the predetermined part of the first supporting part, and wherein, a part of the seventh supporting part may be disposed under a predetermined part of the second supporting part adjacent to the fifth supporting part, and the seventh supporting part is connected to the lower part of the predetermined part of the second supporting part.

[0030] The display device may further include oil layers respectively disposed on a part of the sixth supporting part overlapping with the fifth supporting part and a part of the seventh supporting part overlapping with the fifth supporting part, wherein, the sixth supporting part may be integrally provided with the first supporting part, and the seventh supporting part may be integrally provided with the second supporting part.

[0031] It will be understood that the above summary description and the following detailed description are exemplary and illustrative, and are intended to provide further illustration of the claimed invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The accompanying drawings provide a further understanding of the present invention, and are incorporated into and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present invention and, together with the description, are used to explain the inventive concept.

[0033] Figure 1 is a cross-sectional view of a display device according to an exemplary embodiment of the present disclosure.

[0034] Figure 2 is Figure 1 a top view of the upper surface of the display device shown in

[0035] Figure 3 is arranged in Figure 1 a cross-sectional view of a pixel in the display module shown in

[0036] Figure 4 is a view showing Figure 1 an enlarged view of at least a part of the supporting member and the display module shown in

[0037] Figure 5 shows Figure 4 the folded state of the supporting member and the display module shown in

[0038] Figure 6A 、 Figure 6B 、 Figure 6C 、 Figure 7 、 Figure 8 、 Figure 9 and Figure 10 show a manufacturing method of a display device according to an exemplary embodiment of the present disclosure.

[0039] Figure 11is an enlarged view showing at least a part of a support member and a display module according to an exemplary embodiment of the present disclosure.

[0040] Figure 12 shows Figure 11 the folded state of the support member and the display module shown in

[0041] Figure 13 is an enlarged view showing at least a part of a support member and a display module according to an exemplary embodiment of the present disclosure.

[0042] Figure 14 shows Figure 13 the folded state of the support member and the display module shown in

[0043] Figure 15 is an enlarged view showing at least a part of a support member and a display module according to an exemplary embodiment of the present disclosure.

[0044] Figure 16 shows Figure 15 the folded state of the support member and the display module shown in

[0045] Figure 17 is an enlarged view showing at least a part of each of a support member and a display module according to an exemplary embodiment of the present disclosure.

[0046] Figure 18 shows Figure 17 the folded state of the support member and the display module shown in Detailed Description

[0047] In the following description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of various exemplary embodiments or implementations of the present invention. As used herein, "embodiment" and "implementation" are interchangeable words that are non-limiting examples of a device or method that employs one or more of the inventive concepts disclosed herein. However, it will be apparent that the various exemplary embodiments may be practiced without these specific details or with one or more equivalent arrangements. In other instances, well-known structures and devices are shown in block diagram form to avoid unnecessarily obscuring the various exemplary embodiments. Additionally, the various exemplary embodiments may be different, but not necessarily exclusive. For example, without departing from the inventive concept, a particular shape, configuration, and characteristics of one exemplary embodiment may be used or implemented in another exemplary embodiment.

[0048] Unless otherwise specified, the illustrated exemplary embodiments should be understood to provide exemplary features of some ways that can implement the inventive concept in practice. Thus, without departing from the inventive concept, unless otherwise specified, features, components, modules, layers, films, panels, regions, and / or aspects, etc. (hereinafter individually or collectively referred to as "elements") of various embodiments can be combined, separated, interchanged, and / or rearranged in other ways.

[0049] The use of cross-hatching and / or shading in the drawings is generally provided to clarify the boundaries between adjacent elements. Thus, unless specified, the presence or absence of cross-hatching or shading does not express or imply any preference or requirement for a particular material, material property, dimension, ratio, commonality between the elements shown, and / or any other characteristic, attribute, property, etc. of the element. Additionally, in the drawings, for clarity and / or descriptive purposes, the dimensions and relative dimensions of the elements may be exaggerated. When the exemplary embodiments can be implemented differently, a particular process order may be performed differently from the described order. For example, two consecutively described processes may be performed substantially simultaneously or in an order opposite to the described order. Further, the same reference numerals refer to the same elements.

[0050] When an element such as a layer is referred to as being "on," "connected to," or "coupled to" another element or layer, the element can be directly on, directly connected to, or directly coupled to the other element or layer, or intervening elements or layers may be present. However, when an element or layer is referred to as being "directly" on, "directly connected to," or "directly coupled to" another element or layer, no intervening elements or layers are present. For this reason, the term "connected" can refer to physical connection, electrical connection, and / or fluid connection with or without intervening elements. Additionally, the D1 axis, D2 axis, and D3 axis are not limited to the three axes of a rectangular coordinate system, such as the x-axis, y-axis, and z-axis, and can be interpreted in a broader sense. For example, the D1 axis, D2 axis, and D3 axis may be perpendicular to each other, or may represent different directions that are not perpendicular to each other. For the purposes of this disclosure, "at least one of X, Y, and Z" and "at least one selected from the group consisting of X, Y, and Z" can be interpreted as only X, only Y, only Z, or any combination of two or more of X, Y, and Z, such as, for example, XYZ, XYY, YZ, and ZZ. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0051] Although the terms "first", "second", etc. may be used herein to describe various types of elements, these elements should not be limited by these terms. These terms are used to distinguish one element from another. Thus, without departing from the teachings of this disclosure, a first element discussed below could be termed a second element.

[0052] Spatial relative terms such as "below", "beneath", "under", "lower", "above", "upper", "on", "higher", "side" (e.g., as in "sidewall") and the like may be used herein for descriptive purposes and, thus, to describe the relationship of one element to another (or elements) as shown in the figures. Except for the orientation depicted in the figures, the spatial relative terms are intended to encompass different orientations of the device in use, operation, and / or manufacture. For example, if the device in the figures is flipped, an element described as "below" or "beneath" another element or feature would then be oriented "above" the other element or feature. Thus, the exemplary term "below" can encompass both an above and a below orientation. Additionally, the device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations), and, thus, the spatial relative descriptors used herein should be interpreted accordingly.

[0053] The terms used herein are for the purpose of describing particular embodiments and are not intended to be limiting. As used herein, unless the context clearly dictates otherwise, the singular forms "a", "an", and "the" are intended to include the plural forms as well. Additionally, when used in this specification, the terms "comprising", "comprises", "including", and / or "includes" specify the presence of the stated features, integers, steps, operations, elements, components, and / or combinations thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or combinations thereof. It should also be noted that, as used herein, the terms "substantially", "about", and other similar terms are used as approximate terms and not as terms of degree, and, thus, are used to account for inherent deviations in measured, calculated, and / or provided values that would be recognized by one of ordinary skill in the art.

[0054] In this document, various exemplary embodiments are described with reference to cross-sectional views and / or exploded views that are schematic diagrams of ideal exemplary embodiments and / or intermediate structures. Thus, variations in the illustrated shapes are to be expected due to, for example, manufacturing techniques and / or tolerances. Accordingly, the exemplary embodiments disclosed herein should not necessarily be construed as limited to the particular shown shapes of regions, but will include, for example, deviations in shapes due to manufacturing. In this manner, the regions shown in the figures are schematic in nature and the shapes of these regions may not reflect the actual shape of regions of the device and, thus, are not necessarily intended to be limiting.

[0055] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0056] Figure 1 is a cross-sectional view of a display device 100 according to an exemplary embodiment of the present disclosure. Figure 2 is Figure 1 a top view of the upper surface of the display device 100 shown in

[0057] Referring to Figure 1 and Figure 2 , the display device 100 according to the present disclosure has a rectangular shape defined by a pair of long sides extending in a first direction DR1 and a pair of short sides extending in a second direction DR2 that intersects the first direction DR1. However, according to different exemplary embodiments, the display device 100 may have various shapes. Hereinafter, a direction substantially perpendicular to the plane defined by the first direction DR1 and the second direction DR2 will be referred to as a third direction DR3.

[0058] The display device 100 includes a display module DM, a support member SPM, a hinge member HGM, and a housing CS. The display module DM may include a display panel for displaying an image, a touch panel disposed above the display panel to sense a user's touch, and a window disposed above the touch panel to protect the display panel and the touch panel. However, the inventive concept is not limited thereto, and the display panel may include a touch sensor used in the touch panel.

[0059] The display panel may be an organic light-emitting display panel including a plurality of organic light-emitting elements, but it should not be limited thereto or thereby restricted. That is, various display panels for displaying an image (e.g., a liquid crystal display panel, an electro-wetting display panel, an electrophoretic display panel, etc.) may be used as the display panel of the present disclosure.

[0060] The display panel may be a flexible display panel. For example, the display panel may include a substrate formed of a flexible plastic material and a plurality of electronic components (e.g., transistors) disposed on the substrate to drive the organic light-emitting elements. The display panel may include a plurality of pixels disposed thereon, and the pixels may include organic light-emitting elements and electronic components.

[0061] The display module DM and the hinge member HGM are accommodated in the housing CS. The housing CS includes a first housing CS1 and a second housing CS2 that are arranged adjacent to each other in a first direction DR1. When the display device 100 is folded and rotated with respect to the rotation axis, the first housing CS1 and the second housing CS2 are separated from each other.

[0062] The hinge member HGM is provided at the center of the display device 100 to set the first rotation axis AX1 and the second rotation axis AX2 to the center of the display device 100. The first rotation axis AX1 and the second rotation axis AX2 are adjacent to each other and parallel to a second direction DR2. The first housing CS1 is connected to the hinge member HGM and rotates with respect to the first rotation axis AX1. The second housing CS2 is connected to the hinge member HGM and rotates with respect to the second rotation axis AX2.

[0063] The hinge member HGM includes a hinge housing HGC and a plurality of gear units GA1, GA2, and SGA accommodated in the hinge housing HGC. The gear units GA1, GA2, and SGA include a first gear unit GA1 that provides the first rotation axis AX1, a second gear unit GA2 that provides the second rotation axis AX2, and a plurality of sub-gear units SGA disposed between the first gear unit GA1 and the second gear unit GA2.

[0064] When observed in the second direction DR2, the outer circumferential surface of each of the first gear unit GA1, the second gear unit GA2, and the sub-gear unit SGA has a gear shape. The first gear unit GA1, the second gear unit GA2, and the sub-gear unit SGA are arranged to mesh with each other, thereby rotating the first gear unit GA1, the second gear unit GA2, and the sub-gear unit SGA.

[0065] The support member SPM is connected to the hinge member HGM and rotates with respect to the first rotation axis AX1 and the second rotation axis AX2. Reference will be made Figure 4 and Figure 5 to describe the configuration of the support member SPM in detail.

[0066] The display module DM is provided on the support member SPM and is folded when the support member SPM rotates with respect to the first rotation axis AX1 and the second rotation axis AX2. The display module DM includes a non-folded portion NFA and a folded portion FA provided between the non-folded portions NFA. The folded portion FA and the non-folded portion NFA are arranged in the first direction DR1.

[0067] Figure 2An exemplary embodiment including a folding portion FA and two non-folding portions NFA is shown. According to the exemplary embodiment, each of the two non-folding portions NFA may be disposed on a respective side of a folding portion FA. However, the number of non-folding portions NFA should not be limited to two, and the number of folding portions FA should not be limited to one.

[0068] When the display device 100 is folded, the support member SPM rotates relative to the first rotation axis AX1 and the second rotation axis AX2 through the hinge member HGM to be folded, and the display module DM is folded through the support member SPM. When the display module DM is folded, the folding portion FA of the display module DM bends such that the non-folding portions NFA face each other. When the display device 100 is folded, the display module DM can be folded inward (i.e., in the inward folding state) to prevent the display module DM from being exposed to the outside through the housing CS.

[0069] Figure 3 is arranged in Figure 1 A cross-sectional view of a pixel PX in the display module DM shown in

[0070] Referring to Figure 3 , the pixel PX includes an organic light-emitting diode OLED and a transistor TR connected to the organic light-emitting diode OLED. The transistor TR and the organic light-emitting diode OLED are disposed on the base substrate BS.

[0071] The base substrate BS is a transparent flexible substrate. As an example, the base substrate BS includes a flexible plastic material, such as polyimide (PI). A buffer layer BFL is disposed on the base substrate BS and includes an inorganic material.

[0072] The semiconductor layer SM of the transistor TR is disposed on the buffer layer BFL. The semiconductor layer SM may include an inorganic semiconductor material such as amorphous silicon or polysilicon or an organic semiconductor material. In addition, the semiconductor layer SM may include an oxide semiconductor. The semiconductor layer SM includes a source region, a drain region, and a channel region defined between the source region and the drain region.

[0073] A first insulating layer INS1 is disposed on the buffer layer BFL to cover the semiconductor layer SM. The first insulating layer INS1 includes an inorganic material. The gate electrode GE of the transistor TR is disposed on the first insulating layer INS1 to overlap the semiconductor layer SM. The gate electrode GE is disposed to overlap the channel region of the semiconductor layer SM.

[0074] A second insulating layer INS2 is disposed on the first insulating layer INS1 to cover the gate electrode GE. The second insulating layer INS2 may be, but is not limited to, an interlayer insulating layer. The second insulating layer INS2 includes an organic material and / or an inorganic material.

[0075] The source electrode SE and the drain electrode DE of the transistor TR are disposed on the second insulating layer INS2 to be spaced apart from each other. The source electrode SE is connected to the source region of the semiconductor layer SM through a first contact hole CH1 defined through the first insulating layer INS1 and the second insulating layer INS2. The drain electrode DE is connected to the drain region of the semiconductor layer SM through a second contact hole CH2 defined through the first insulating layer INS1 and the second insulating layer INS2.

[0076] A third insulating layer INS3 is disposed on the second insulating layer INS2 to cover the source electrode SE and the drain electrode DE of the transistor TR. The third insulating layer INS3 may be a planarization layer providing a flat upper surface and may include an organic material.

[0077] The first electrode E1 of the organic light-emitting diode OLED is disposed on the third insulating layer INS3. The first electrode E1 is connected to the drain electrode DE of the transistor TR through a third contact hole CH3 defined through the third insulating layer INS3. The first electrode E1 may be referred to as a pixel electrode or an anode electrode. The first electrode E1 may include a transmissive electrode or a reflective electrode.

[0078] A pixel defining layer PDL is disposed on the first electrode E1 and the third insulating layer INS3 such that a part of the first electrode E1 is exposed. An opening OP exposing a part of the first electrode E1 is defined by the pixel defining layer PDL, and a region defined by the opening OP may be referred to as a pixel region PA. A peripheral region of the pixel region PA may be referred to as a non-pixel region NPA.

[0079] In the opening OP, an organic light-emitting layer OEL is disposed on the first electrode E1. The organic light-emitting layer OEL includes an organic material that generates one of red light, green light, and blue light. The organic light-emitting layer OEL generates one of red light, green light, and blue light. However, according to another embodiment, the organic light-emitting layer OEL may generate white light obtained by combining organic materials that respectively generate red light, green light, and blue light.

[0080] A second electrode E2 is disposed on the pixel defining layer PDL and the organic light-emitting layer OEL. The second electrode E2 may be a common electrode or a cathode electrode. The second electrode E2 may include a transmissive electrode or a reflective electrode.

[0081] In the case where the display panel is a front surface emission type organic light-emitting display panel, a reflective electrode is used as the first electrode E1, and a transmissive electrode is used as the second electrode E2. In the case where the display panel is a back surface emission type organic light-emitting display panel, a transmissive electrode is used as the first electrode E1, and a reflective electrode is used as the second electrode E2.

[0082] The organic light-emitting diode OLED is disposed in the pixel region PA and includes a first electrode E1, an organic light-emitting layer OEL, and a second electrode E2 located in the pixel region PA. The first electrode E1 may be an anode electrode serving as a hole injection electrode, and the second electrode E2 may be a cathode electrode serving as an electron injection electrode.

[0083] The thin film encapsulation layer TFE is disposed on the organic light-emitting diode OLED to cover the pixel PX. Specifically, the thin film encapsulation layer TFE is disposed on the second electrode E2. The thin film encapsulation layer TFE includes an organic material and / or an inorganic material.

[0084] To allow the organic light-emitting layer OEL to emit light, a first voltage is applied to the first electrode E1 through the transistor TR, and a second voltage having a polarity opposite to that of the first voltage is applied to the second electrode E2. Holes and electrons are injected into the organic light-emitting layer OEL and recombine in the organic light-emitting layer OEL to generate excitons. When the excited-state excitons return to the ground state, the organic light-emitting diode OLED emits light. The organic light-emitting diode OLED emits red, green, or blue light according to the flow of current to display predetermined image information.

[0085] Figure 4 is a magnified view showing Figure 1 at least a part of the support member SPM and the display module DM shown in Figure 5 shows Figure 4 the folded state of the support member SPM and the display module DM shown in

[0086] For convenience of explanation, Figure 4 and Figure 5 show the folding part FA and a part of the non-folding part NFA adjacent to the folding part FA of the display module DM.

[0087] Referring to Figure 4 and Figure 5 , when the display module DM is folded, the folding part FA bends, and the non-folding part NFA remains flat and is arranged opposite to each other. The folding part FA rotates about a rotation axis parallel to the second direction DR2 (e.g., Figure 1 the first rotation axis AX1 and the second rotation axis AX2 shown in

[0088] The support member SPM can be disposed under the rear surface of the display module DM, and the rear surface of the display module DM is opposite to the front surface of the display image of the display module DM. The support member SPM includes a first support member SPM1 disposed under the rear surface of the display module DM and a second support member SPM2 disposed between the rear surface of the display module DM and the first support member SPM1. The first support member SPM1 includes a metallic material, and the second support member SPM2 includes an elastic material. For example, the first support member SPM1 includes aluminum or stainless steel. The second support member SPM2 includes rubber, silicone, or urethane.

[0089] The adhesive member AD is disposed between the second support member SPM2 and the display module DM. The adhesive member AD attaches the display module DM to the second support member SPM2.

[0090] The first support member SPM1 has a thickness ranging from about 0.1 mm to about 0.5 mm in the third direction DR3. The second support member SPM2 has a thickness ranging from about 0.2 mm to about 0.3 mm in the third direction DR3.

[0091] The first support member SPM1 includes a first support portion SP1, a second support portion SP2, and a plurality of support units SU disposed between the first support portion SP1 and the second support portion SP2. The first support portion SP1 and the second support portion SP2 overlap with the non-folded portion NFA, and the support units SU overlap with the folded portion FA. Figure 4 and Figure 5 A cross-section of each of the support units SU is shown, and the support units SU can extend in the second direction DR2.

[0092] When the display device 100 is folded inward (i.e., in the inward-folded state), the inner surface of the display module DM can refer to the surfaces of the non-folded portion NFA that face each other and the surfaces of the folded portion FA that extend from the surfaces of the non-folded portion NFA that face each other. The surfaces of the folded portion FA and the surfaces of the non-folded portion NFA can be an integrally formed single surface. The outer surface of the display module DM can refer to the surface opposite to the inner surface of the display module DM. The inner surface of the display module DM can be the front surface for displaying an image of the display module DM, and the outer surface of the display module DM can be the rear surface of the display module DM.

[0093] Since the second supporting member SPM2 including an elastic material is disposed on the outer surface of the display module DM, when the display device 100 is folded inwardly (i.e., inwardly folded state), the folding portion FA can be easily bent. The supporting unit SU is disposed under the folding portion FA, and when the display device 100 is folded inwardly (i.e., inwardly folded state), the gap between the supporting units SU spaced apart from each other along the folding portion FA can be widened. Therefore, although the supporting unit SU includes a metal material, the folding portion FA can be easily bent.

[0094] When the supporting member SPM is not disposed at the folding portion FA, foreign matter adheres to the outer surface of the folding portion FA, and thus the folding portion FA may be damaged. In addition, the folding portion FA may be deformed due to repeated folding actions. In an exemplary embodiment of the present disclosure, since the second supporting member SPM2 covers the outer surface of the display module DM, when the display device 100 is folded inwardly (i.e., inward folding state), the outer surface of the folding portion FA is not exposed to the outside. Therefore, foreign matter does not adhere to the outer surface of the folding portion FA, and thus damage to the folding portion FA can be prevented or reduced. In addition, since the second supporting member SPM2 is attached to the display module DM to support the display module DM, deformation of the folding portion FA can be prevented or reduced.

[0095] Since the second supporting member SPM2 has elasticity, when the display module DM is unfolded, the display module DM can be supported flatly by the second supporting member SPM2. The first supporting member SPM1 including a metal material has a relatively rigid structure, and thus when the display module DM is unfolded, the display module DM can be supported more flatly by the first supporting member SPM1. In addition, since the folding portion FA is more firmly supported by the first supporting member SPM1 having a rigid structure, the folding portion FA can be less deformed.

[0096] Therefore, according to the display apparatus 100 , the support member SPM protecting the folded portion FA of the display module DM is disposed under the folded portion FA, and thus damage and deformation of the folded portion FA may be prevented or reduced.

[0097] Figure 6A , Figure 6B , Figure 6C , Figure 7 , Figure 8 , Figure 9 and Figure 10 A method of manufacturing a display device according to an exemplary embodiment of the present disclosure is illustrated.

[0098] refer to Figure 6A , Figure 6B and Figure 6C, a first support member SPM1 is prepared, and a plurality of cutting grooves CG are formed in a first surface OS1 of the first support member SPM1. The first surface OS1 of the first support member SPM1 may be a flat surface substantially parallel to a first direction DR1 and a second direction DR2. A surface opposite to the first surface OS1 of the first support member SPM1 may be referred to as a second surface OS2.

[0099] Each of the cutting grooves CG has a depth DP that is equal to or greater than half of the thickness T of the first support member SPM1 and less than the thickness T of the first support member SPM1 in a third direction DR3. The cutting grooves CG may extend in the second direction DR2.

[0100] The first support member SPM1 includes a folding area FA' corresponding to a folding part FA of the display module DM and a non-folding area NFA' corresponding to a non-folding part NFA of the display module DM. The cutting grooves CG are defined in the first surface OS1 of the first support member SPM1 corresponding to the folding area FA'. The cutting grooves CG can be formed in a variety of ways.

[0101] For example, referring to Figure 6A the exemplary embodiment shown in, a pressing unit PU may be disposed above the first surface OS1 of the folding area FA'. The pressing unit PU applies a predetermined pressure to the first surface OS1 of the folding area FA' to form the cutting grooves CG in the first surface OS1 of the folding area FA'.

[0102] Referring to Figure 6B the exemplary embodiment shown in, a photoresist PR may be disposed on the first surface OS1 of the first support member SPM1. A plurality of portions of the photoresist PR corresponding to a plurality of portions of the folding area FA' are removed to form the cutting grooves CG. The portions of the first support member SPM1 exposed by the removed portions of the photoresist PR are exposed.

[0103] Then, using the photoresist PR as a mask, the portion of the first support member SPM1 in which the cutting grooves CG are formed is etched (ET). The time of the etching (ET) process is controlled such that the portion of the first support member SPM1 exposed by the photoresist PR is etched to a predetermined depth and not completely etched. Thus, the cutting grooves CG can be defined in the first surface OS1 of the folding area FA'.

[0104] Referring to Figure 6C the exemplary embodiment shown in, a laser unit LU may be disposed above the first surface OS1 of the folding area FA'. The laser unit LU irradiates a laser LS onto the first surface OS1 of the folding area FA' to define the cutting grooves CG in the first surface OS1 of the folding area FA'.

[0105] Referring to Figure 7, a second support member SPM2 is provided on a second surface OS2 of the first support member SPM1. In Figure 7 In, a first surface OS1 of the first support member SPM1 may be a lower surface of the first support member SPM1, and a second surface OS2 of the first support member SPM1 may be an upper surface of the first support member SPM1.

[0106] The second support member SPM2 may be provided on the first support member SPM1 by a compression molding process or an injection molding process. An elastic material having fluidity is provided on the first support member SPM1 and cured to form the second support member SPM2. When the elastic material having fluidity is cured, the second support member SPM2 may be attached to the first support member SPM1.

[0107] Reference Figure 8 , a display module DM is provided on the second support member SPM2, and an adhesive member AD is provided between the display module DM and the second support member SPM2. The display module DM may be attached to the second support member SPM2 through the adhesive member AD.

[0108] Reference Figure 9 , the first support member SPM1 and the second support member SPM2 are folded, and thus the display module DM is folded inward (i.e., in an inward folding state). A folding portion FA and a folding region FA' are rotated with respect to a rotation axis substantially parallel to a second direction DR2 (e.g., Figure 1 the first rotation axis AX1 and the second rotation axis AX2 shown in) to be bent.

[0109] When the folding portion FA and the folding region FA' are bent, stress is applied in the folding region FA' of the first support member SPM1. A portion of the folding region FA' corresponding to the cutting groove CG may be cut due to the stress. Therefore, a plurality of support units SU may be formed in the folding region FA'. In addition, according to the division of the portion of the folding region FA', a first support portion SP1 and a second support portion SP2 may be formed.

[0110] Reference Figure 10 , the display module DM and the first support member SPM1 and the second support member SPM2 are unfolded. Since the support units SU are formed in the folding region FA', the first support member SPM1 may include a first support portion SP1, a second support portion SP2, and the support units SU provided between the first support portion SP1 and the second support portion SP2.

[0111] In an exemplary embodiment of the present disclosure, one first support member SPM1 may be used, and the first support member SPM1 may be divided by the cutting groove CG, thereby forming the support units SU, the first support portion SP1, and the second support portion SP2.

[0112] According to a comparative embodiment, in this comparative embodiment, the support unit SU is formed separately without using the cutting groove CG, and the second support member SPM2 can be prepared separately and disposed on the separately formed support unit SU. In addition, the first support part SP1 and the second support part SP2 need to be prepared separately. In this case, the separated support unit SU needs to be disposed between the first support part SP1 and the second support part SP2. However, a process of accurately aligning the first support part SP1 and the second support part SP2 with the separated support unit SU is required, and thus, the process becomes complicated.

[0113] In addition, even if the first support part SP1 and the second support part SP2 are accurately aligned with the support unit SU, the alignment between the first support part SP1 and the second support part SP2 and the support unit SU may be broken due to the weight and flow of the flowable elastic material provided on the first support part SP1, the second support part SP2, and the support unit SU to form the second support member SPM2.

[0114] However, according to an exemplary embodiment of the present disclosure, after the cutting groove CG is formed in the folding area FA' of the first support member SPM1, the second support member SPM2 is disposed on the first support member SPM1. When the display module DM is attached to the second support member SPM2, the folding area FA' of the first support member SPM1 is bent, and thus, the first support part SP1, the second support part SP2, and the support unit SU can be formed. Therefore, it is not necessary to separately prepare the first support part SP1, the second support part SP2, and the support unit SU, and thus, a process of aligning the first support part SP1 and the second support part SP2 with the support unit SU is not required.

[0115] Therefore, a manufacturing method of the display device 100 according to an exemplary embodiment of the present disclosure can be simplified.

[0116] Figure 11 is an enlarged view showing at least a part of a support member SPM_1 and a display module DM of a display device according to an exemplary embodiment of the present disclosure. Figure 12 shows Figure 11 a folded state of the support member SPM_1 and the display module DM shown in

[0117] For convenience of explanation, Figure 11 and Figure 12 show elements corresponding to the elements shown in Figure 4 and Figure 5 Except for the support member SPM_1, Figure 11 and Figure 12 the elements shown in Figure 4 and Figure 5The components shown are substantially the same. Therefore, mainly Figure 11 and Figure 12 the configuration of the support member SPM_1 shown in Figure 4 and Figure 5 which is different from the configuration of the support member SPM will be described, and the same components will be assigned the same reference numerals.

[0118] Referring to Figure 11 and Figure 12 , the display module DM includes a folding portion FA and a non-folding portion NFA. The support member SPM_1 includes a first support member SPM1_1 and a second support member SPM2_1, and the first support member SPM1_1 is disposed under the display module DM. The first support member SPM1_1 includes a metallic material. The first support member SPM1_1 includes a first support portion SP1 and a second support portion SP2 that respectively overlap the non-folding portion NFA of the display module DM.

[0119] The second support member SPM2_1 includes a third support portion SP3, a fourth support portion SP4, and a fifth support portion SP5. The third support portion SP3, the fourth support portion SP4, and the fifth support portion SP5 may be integrally formed as a single body. The second support member SPM2_1 may be disposed between the non-folding portion NFA of the display module DM and the first support portion SP1 and the second support portion SP2. In addition, the second support member SPM2_1 may be disposed between the first support portion SP1 and the second support portion SP2. The second support member SPM2_1 may include an elastic material having a predetermined elasticity. The second support member SPM2_1 may be disposed on the first support member SPM1_1 by the compression molding process or the injection molding process mentioned above. The display module DM may be attached to the second support member SPM2_1 by an adhesive member AD.

[0120] The second support member SPM2_1 includes a third support portion SP3 disposed between the first support portion SP1 and the non-folding portion NFA of the display module DM disposed on the first support portion SP1, a fourth support portion SP4 disposed between the second support portion SP2 and the non-folding portion NFA of the display module DM disposed on the second support portion SP2, and a fifth support portion SP5 disposed between the first support portion SP1 and the second support portion SP2.

[0121] The fifth support portion SP5 includes a plurality of protrusions PT, and the protrusions PT extend in a second direction DR2. According to an exemplary embodiment, the protrusions PT protrude in a third direction DR3 beyond the lower surfaces of each of the first support portion SP1 and the second support portion SP2.

[0122] Since the second support member SPM2_1 having a predetermined elasticity is provided on the outer surface of the display module DM, the folding portion FA can be easily bent. In addition, as Figure 12 shown, when the folding portion FA is bent, the protrusions PT are spaced apart from each other, and thus the folding portion FA can be bent more easily.

[0123] Since the second support member SPM2_1 covers the outer surface of the display module DM, foreign matter does not adhere to the outer surface of the folding portion FA, and thus, damage to the folding portion FA can be prevented. In addition, since the fifth support portion SP5 has a thickness greater than the thicknesses of the third support portion SP3 and the fourth support portion SP4, the fifth support portion SP5 can more firmly support the folding portion FA of the display module DM. Accordingly, deformation of the folding portion FA can be prevented.

[0124] Figure 13 is an enlarged view showing at least a part of the support member SPM_2 and the display module DM according to an exemplary embodiment of the present disclosure. Figure 14 shows Figure 13 the folded state of the support member SPM_2 and the display module DM shown in

[0125] Except for the second support member SPM2_2 of the support member SPM_2, Figure 13 and Figure 14 the elements shown in Figure 11 and Figure 12 are substantially the same as the elements shown in Figure 13 and Figure 14 Therefore, the configuration of the second support member SPM2_2 shown in Figure 11 and Figure 12 which is different from the configuration of the second support member SPM2_1 shown in

[0126] will be mainly described, and the same elements will be assigned the same reference numerals. Figure 13 and Figure 14 Referring to

[0127] the first support member SPM1_2 includes a first support portion SP1 and a second support portion SP2, and the second support member SPM2_2 includes a third support portion SP3, a fourth support portion SP4, and a fifth support portion SP5'.

[0128] Since the second support member SPM2_2 having a predetermined elasticity is disposed on the outer surface of the display module DM, the folding portion FA can be easily bent. The second support member SPM2_2 covers the outer surface of the display module DM, and thus foreign matter does not adhere to the outer surface of the folding portion FA, and damage to the folding portion FA can be prevented. In addition, since the fifth support portion SP5' has a thickness greater than the thickness of each of the third support portion SP3 and the fourth support portion SP4, the fifth support portion SP5' can more firmly support the folding portion FA of the display module DM. Therefore, deformation of the folding portion FA can be prevented.

[0129] Figure 15 is an enlarged view showing at least a part of the support member SPM_3 and the display module DM of a display device according to an exemplary embodiment of the present disclosure. Figure 16 Shows Figure 15 the folded state of the support member SPM_3 and the display module DM shown in

[0130] Except for the sixth support portion SP6 and the seventh support portion SP7, Figure 15 and Figure 16 the configuration of the support member SPM_3 shown in Figure 13 and Figure 14 is substantially the same as the configuration of the support member SPM_2 shown in Figure 15 and Figure 16 Therefore, the configuration of the support member SPM_3 shown in Figure 13 and Figure 14 which is different from the configuration of the support member SPM_2 shown in

[0131] Referring to Figure 15 and Figure 16 , the support member SPM_3 includes a sixth support portion SP6 disposed under the fifth support portion SP5' and the first support portion SP1, and a seventh support portion SP7 disposed under the fifth support portion SP5' and the second support portion SP2. The sixth support portion SP6 and the seventh support portion SP7 include a metal material.

[0132] A portion of the sixth support portion SP6 disposed under a predetermined portion WEL of the first support portion SP1 adjacent to the fifth support portion SP5' can be connected to the lower portion of the predetermined portion WEL of the first support portion SP1. The predetermined portion WEL of the first support portion SP1 can be referred to as a welding region WEL. The sixth support portion SP6 can be connected to the welding region WEL of the first support portion SP1 by welding.

[0133] The portion of the seventh support portion SP7 disposed below a predetermined portion WEL' of the second support portion SP2 adjacent to the fifth support portion SP5' may be connected to the lower portion of the predetermined portion WEL' of the second support portion SP2. The predetermined portion WEL' of the second support portion SP2 may be referred to as a welding area WEL'. The seventh support portion SP7 may be connected to the welding area WEL' of the second support portion SP2 by welding. The sixth support portion SP6 and the seventh support portion SP7 are spaced apart from each other with respect to the center of the fifth support portion SP5'.

[0134] When the second support member SPM2_3 is disposed on the first support member SPM1_3 by a compression molding process or an injection molding process, the sixth support portion SP6 and the seventh support portion SP7 may be respectively connected to the welding areas WEL and WEL'. Since the second support member SPM2_3 is already in a cured state, portions of the sixth support portion SP6 other than the welding area WEL and portions of the seventh support portion SP7 other than the welding area WEL' are not attached to the fifth support portion SP5'.

[0135] Since the second support member SPM2_3 having a predetermined elasticity is disposed on the outer surface of the display module DM and the sixth support portion SP6 and the seventh support portion SP7 are not attached to the fifth support portion SP5', the folding portion FA can be easily bent. Since the second support member SPM2_3 covers the outer surface of the display module DM, damage and deformation of the folding portion FA can be prevented. When the display module DM is unfolded, the sixth support portion SP6 and the seventh support portion SP7 having a structure more rigid than that of the fifth support portion SP5' are disposed below the fifth support portion SP5', and thus can more firmly support the display module DM.

[0136] Figure 17 is an enlarged view showing at least a part of each of the support member SPM_4 and the display module DM according to an exemplary embodiment of the present disclosure. Figure 18 Shows Figure 17 the folded state of the support member SPM_4 and the display module DM shown in

[0137] Except for the configuration of the first support member SPM1_4 of the support member SPM_4, Figure 17 and Figure 18 the configuration of the support member SPM_4 shown in Figure 15 and Figure 16 is substantially the same as the configuration of the support member SPM_3 shown in Figure 17 and Figure 18 Therefore, the description will mainly focus on Figure 15 and Figure 16The configuration of the support member SPM_4 is different from that of the support member SPM_3 shown, and the same elements will be assigned the same reference numerals.

[0138] Reference Figure 17 and Figure 18 , the first support member SPM1_4 includes a sixth support portion SP6' and a seventh support portion SP7'. The sixth support portion SP6' is disposed below the fifth support portion SP5' and the first support portion SP1. The seventh support portion SP7' is disposed below the fifth support portion SP5' and the second support portion SP2.

[0139] The first support portion SP1 and the sixth support portion SP6' are integrally formed with each other, and the second support portion SP2 and the seventh support portion SP7' are integrally formed with each other. The sixth support portion SP6' completely overlaps the first support portion SP1, and the seventh support portion SP7' completely overlaps the second support portion SP2.

[0140] An elastic material having fluidity may be disposed on the first support member SPM1_4 to form a second support member SPM2_4. When the elastic material having fluidity cures, the second support member SPM2_4 may be attached to the first support member SPM1_4.

[0141] To prevent the portions of the sixth support portion SP6' and the seventh support portion SP7' that overlap the fifth support portion SP5' from being attached to the fifth support portion SP5', an oil layer OIL may be provided on the portions of the sixth support portion SP6' and the seventh support portion SP7' that overlap the fifth support portion SP5'. Accordingly, even when the elastic material having fluidity cures, the portions of the sixth support portion SP6' and the seventh support portion SP7' that overlap the fifth support portion SP5' may not be attached to the fifth support portion SP5'.

[0142] Since the second support member SPM2_4 having a predetermined elasticity is disposed on the outer surface of the display module DM, and the sixth support portion SP6' and the seventh support portion SP7' are not connected to the fifth support portion SP5', the folding portion FA can be easily bent and damage and deformation of the folding portion FA can be prevented. When the display module DM is unfolded, the sixth support portion SP6' and the seventh support portion SP7' having a structure more rigid than that of the fifth support portion SP5' are disposed below the fifth support portion SP5', and thus the display module DM can be more firmly supported.

[0143] Some advantages that can be achieved by the presently disclosed exemplary embodiments include protecting the folding portion of the display module by using a support portion disposed below the folding portion to reduce damage and / or deformation of the folding portion. In addition, the manufacturing method of the display device can be simplified.

[0144] Although certain exemplary embodiments and implementations have been described herein, other embodiments and modifications will be apparent from this specification. Accordingly, the inventive concept is not limited to these embodiments, but rather to the broader scope of the appended claims and to various obvious modifications and equivalent arrangements that will be apparent to those of ordinary skill in the art.

Claims

1. A display device, comprising: a display module including a non-foldable portion and a foldable portion disposed between the non-foldable portions; a first support member disposed under the display module; and wherein the first support member includes: a first support portion and a second support portion, the first support portion and the second support portion overlapping with the non-foldable portion; and a plurality of support units overlapping with the foldable portion and spaced apart from each other by a plurality of cutting grooves, wherein a side surface of the first support portion facing the plurality of support units has an inclined surface forming a first acute angle with a surface of the first support portion facing the display module; and wherein a side surface of the second support portion facing the plurality of support units has an inclined surface forming a second acute angle with a surface of the second support portion facing the display module.

2. The display device according to claim 1, further comprising a second support member disposed between the display module and the first support member.

3. The display device according to claim 2, wherein, The first support member includes a metallic material, and wherein the second support member includes an elastic material.

4. The display device according to claim 3, wherein The first support member includes aluminum or stainless steel, and wherein the second support member includes rubber, silicone, or urethane.

5. The display device according to claim 2, further comprising an adhesive member attaching the display module to the second support member.

6. The display device according to claim 2, wherein, The second support member is attached to the first support member.

7. The display device according to claim 2, wherein, When the display module and the first support member are unfolded, the foldable portion and the non-foldable portion are arranged in a first direction, and the support units extend in a second direction intersecting the first direction.

8. The display device according to claim 7, wherein, The foldable portion is configured to rotate relative to a rotation axis parallel to the second direction to fold the display module, and wherein the support units are spaced apart from each other along the foldable portion in the first direction, and the display module is folded inwardly without being exposed to the outside.

9. The display device according to claim 7, wherein, The first support member has a thickness ranging from 0.1 mm to 0.5 mm in a third direction perpendicular to a plane defined by the first direction and the second direction.

10. The display device according to claim 9, wherein, The second support member has a thickness ranging from 0.2 mm to 0.3 mm in the third direction.

11. A method of manufacturing a display device, comprising: forming a plurality of first cutting grooves on a lower surface of a folding region of a first support member, the folding region of the first support member being disposed between non-foldable regions of the first support member; disposing a second support member on the first support member; disposing a display module on the second support member; bending the folding region and a foldable portion of the display module overlapping the folding region to fold the display module inwardly; and When the display module is folded, the plurality of first cutting grooves form a plurality of second cutting grooves, wherein the depth of the plurality of second cutting grooves is greater than the depth of the plurality of first cutting grooves, and the first support member is divided by the plurality of second cutting grooves to form a first support portion and a second support portion of the first support member, and a plurality of support units disposed between the first support portion and the second support portion, overlapping with the folding area and spaced apart from each other by the second cutting grooves; Wherein, when the display module and the first support member are unfolded, the folding area and the non-folding area are arranged in a first direction, and the second cutting grooves extend in a second direction intersecting the first direction; and Wherein, the folding area and the folding portion are configured to rotate and bend about a rotation axis parallel to the second direction.

12. The method according to claim 11, wherein, Each of the plurality of first cutting grooves has a depth that is equal to or greater than half of the thickness of the first support member and less than the thickness of the first support member in a third direction perpendicular to the plane defined by the first direction and the second direction.

13. The method according to claim 11, wherein, The first support member includes a metallic material, and Wherein, the second support member includes an elastic material.

14. The method according to claim 11, further comprising attaching the display module to the second support member using an adhesive member.

15. The method according to claim 11, Among them, The side surface of the first support portion facing the plurality of support units has an inclined surface that forms a first acute angle with the surface of the first support portion facing the display module; And Wherein, the side surface of the second support portion facing the plurality of support units has an inclined surface that forms a second acute angle with the surface of the second support portion facing the display module.

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