Display device and method of manufacturing the same

Abstract

The application provides a display device and a manufacturing method thereof. The display device comprises a display panel, a sound generating unit arranged on the light emitting side of the display panel, and a vibration unit layer arranged on the side of the sound generating unit away from the display panel; the sound generating unit comprises a first electrode layer, a first metal layer, a first insulating layer, a columnar spacer layer, a second insulating layer, a second metal layer and a second electrode layer which are sequentially and layerwisely arranged along the light emitting direction of the display panel. The display device and the manufacturing method thereof directly manufacture each film layer structure of the sound generating unit on the display panel, save the glass substrate formed by the 1.1T glass substrate, and do not cause the gap caused by external mounting, so that the display device can be thinned.

Description

Technical Field

[0001] This application relates to the field of display technology, and in particular to a display device and a method for manufacturing the same. Background Technology

[0002] Directional audio transmission technology provides an effective way to propagate sound without the need for large speaker arrays. It can project sound in a highly directional manner onto a specific area, creating a precise, quiet, and independent audio space that does not disturb the surrounding environment.

[0003] Currently, directional audio transmission technology is mainly used in audio systems. However, when applied to the field of display technology, the directional audio transmission device can only be externally mounted on the display device. This results in an increase in the thickness of the display device, and the externally mounted directional audio transmission device is difficult to match with the display content of the screen, thus failing to achieve audio-visual integration. Summary of the Invention

[0004] In view of this, the purpose of this application is to provide a display device and a method for manufacturing the same.

[0005] To achieve the above objectives, this application provides a display device, including a display panel, a sound-emitting unit disposed on the light-emitting side of the display panel, and a vibration unit layer disposed on the side of the sound-emitting unit away from the display panel; the sound-emitting unit includes a first electrode layer, a first metal layer, a first insulating layer, a columnar spacer layer, a second insulating layer, a second metal layer, and a second electrode layer, which are sequentially stacked along the light-emitting direction of the display panel.

[0006] Optionally, the first metal layer includes a first metal frame, a first electrode lead, and a second electrode lead. The first metal frame is formed at the edge of the first electrode layer, the first electrode lead is formed at one end of the first electrode layer and connected to the first metal frame, and the second electrode lead is formed at one end of the first electrode layer and electrically insulated from the first metal frame.

[0007] The second metal layer includes a second metal frame, which is connected to the second electrode lead;

[0008] The first electrode lead and the second electrode lead are used to connect to external electrodes.

[0009] Optionally, it also includes an electrical connection unit disposed on the second electrode lead, the second electrode lead being connected to the second metal frame through the electrical connection unit.

[0010] Optionally, the display panel includes a plurality of pixel units;

[0011] The first metal layer further includes a first metal grid line formed within and connected to the first metal frame. The first metal grid line divides the first metal layer into a plurality of first metal grids, and each first metal grid is configured to correspond to one or more pixel units of the display panel.

[0012] And / or,

[0013] The second metal layer further includes a second metal grid line formed within and connected to the second metal frame. The second metal grid line divides the second metal layer into a plurality of second metal grids, and each second metal grid is configured to correspond to one or more pixel units of the display panel.

[0014] Optionally, the orthographic projections of the first metal frame and the first metal mesh line on the display panel are located within the orthographic projection of the first insulating layer on the display panel, and the orthographic projections of the second electrode lead on the display panel do not overlap with the orthographic projections of the first insulating layer on the display panel.

[0015] The orthographic projections of the first electrode lead and the second electrode lead on the display panel do not overlap with the orthographic projection of the second insulating layer on the display panel; the orthographic projections of the second metal frame and the second metal grid line on the display panel are located within the orthographic projection of the second insulating layer on the display panel.

[0016] Optionally, the display panel includes a color filter substrate, and the color filter substrate includes a black matrix;

[0017] The orthogonal projections of the first metal grid line and the second metal grid line on the color filter substrate are located within the black matrix.

[0018] Optionally, the columnar spacer layer includes a plurality of columnar spacers arranged in an array, with sound-emitting sub-units formed between the plurality of columnar spacers, and each sound-emitting sub-unit corresponding to one or more pixel units of the display panel.

[0019] Optionally, the display panel includes a color filter substrate, and the color filter substrate includes a black matrix;

[0020] The orthogonal projection of the columnar spacers onto the color filter substrate lies within the black matrix.

[0021] Optional, also includes:

[0022] A frame adhesive layer is disposed between the first insulating layer and the second insulating layer to bond the first insulating layer and the second insulating layer;

[0023] The frame adhesive layer includes multiple frame adhesive units, and an air circulation channel is provided between two adjacent frame adhesive units. Each air circulation channel has a blocking unit parallel to the frame adhesive unit on the side near the columnar spacer, and the width of the blocking unit is greater than the width of the air circulation channel.

[0024] Optionally, the end of the frame adhesive unit facing the blocking unit is provided with a first extension.

[0025] The end of the blocking unit facing the frame adhesive unit is provided with a second extension.

[0026] Two second extensions are provided between two first extensions disposed on the same frame adhesive unit, and the two second extensions are disposed on different blocking units; two first extensions are provided between two second extensions disposed on the same blocking unit, and the two first extensions are disposed on different frame adhesive units.

[0027] Optionally, the vibration unit layer includes a first polarizer, and the backlight surface of the display panel is provided with a second polarizer;

[0028] or,

[0029] The vibration unit layer includes a protective layer, and a third polarizer is disposed between the display panel and the sound-generating unit, and a second polarizer is disposed on the backlight surface of the display panel.

[0030] This application provides a method for manufacturing a display device, including:

[0031] Provides a display panel and vibration unit layer;

[0032] A first electrode layer, a first metal layer, and a first insulating layer are sequentially formed on the light-emitting side of the display panel, and a second electrode layer, a second metal layer, and a second insulating layer are sequentially formed on the side of the vibration unit layer near the display panel.

[0033] A columnar spacer layer is formed on the first insulating layer or the second insulating layer;

[0034] The first insulating layer and the second insulating layer are bonded together to form the display device.

[0035] Optionally, it may also include at least one of the following:

[0036] A material film layer for forming the first electrode layer is formed on the display panel, and the pattern of the first electrode layer is formed by a patterning process using a photomask.

[0037] A metal thin film is formed on the first electrode layer, and a pattern of the first metal layer is formed by a patterning process using a photomask.

[0038] A thin film of a first insulating layer material is formed on the first metal layer, and a pattern of the first insulating layer is formed by using a photomask and a patterning process.

[0039] A columnar spacer material film is formed on the first insulating layer or the second insulating layer, and the pattern of the columnar spacer layer is formed by a patterning process using a photomask.

[0040] Optionally, the display panel includes a color filter substrate, and the vibration unit layer includes a first polarizer;

[0041] The first electrode layer, the first metal layer, and the first insulating layer are sequentially formed on the light-emitting side of the display panel, including:

[0042] The first electrode layer, the first metal layer, and the first insulating layer are sequentially formed on the color filter substrate;

[0043] The second electrode layer, the second metal layer, and the second insulating layer are sequentially formed on the side of the vibration unit layer near the display panel, including:

[0044] The second electrode layer, the second metal layer, and the second insulating layer are sequentially formed on the side of the first polarizer near the display panel.

[0045] Optionally, a third polarizer is provided on the light-emitting side of the display panel. The third polarizer includes a first adhesive layer, a first protective film, a first linear polarizer, and a second protective film, which are sequentially stacked along the light-emitting direction away from the display panel; the vibration unit layer includes a protective layer.

[0046] The first electrode layer, the first metal layer, and the first insulating layer are sequentially formed on the light-emitting side of the display panel, including:

[0047] A second protective film is provided, on one side of the second protective film the first electrode layer, the first metal layer and the first insulating layer are formed sequentially, and on the other side of the second protective film the first linear polarizer, the first protective film and the first adhesive layer are formed sequentially, and the first adhesive layer is bonded to the display panel;

[0048] The second electrode layer, the second metal layer, and the second insulating layer are sequentially formed on the side of the vibration unit layer near the display panel, including:

[0049] The second electrode layer, the second metal layer, and the second insulating layer are sequentially formed on the side of the protective layer near the display panel.

[0050] Optionally, the display panel includes a color filter substrate, the color filter substrate including a black matrix; the columnar spacer layer includes a plurality of columnar spacers arranged in an array; the process of forming the pattern of the columnar spacer layer using a mask through a patterning process includes:

[0051] The columnar spacers are formed on the first insulating layer or the second insulating layer using a photomask patterning process, such that the orthogonal projection of the columnar spacers on the color filter substrate is located within the black matrix.

[0052] As can be seen from the above, the display device and its manufacturing method provided in this application have the film layer structure of the sound-emitting unit directly fabricated on the display panel. That is, the first electrode layer, first metal layer, first insulating layer, columnar spacer layer, second insulating layer, second metal layer and second electrode layer of the sound-emitting unit are directly formed on the upper glass substrate of the display panel, thereby integrating the sound-emitting unit on the display panel. This can save the glass substrate formed by the 1.1T glass substrate, thereby reducing the thickness of the display device. At the same time, since the film layer structure of the sound-emitting unit is directly fabricated on the display panel, there will be no gaps caused by external mounting, thereby further reducing the thickness of the display device. Attached Figure Description

[0053] To more clearly illustrate the technical solutions in this application or related technologies, the drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0054] Figure 1 This is a schematic diagram of the structure of a display device in the prior art;

[0055] Figure 2 This is a schematic diagram of the structure of the display device described in the embodiments of this application;

[0056] Figures 3a-3f This is a schematic diagram of the structure of the first metal layer in an embodiment of this application;

[0057] Figures 4a-4b This is a schematic diagram of the structure of the second metal layer in an embodiment of this application;

[0058] Figure 5a This is a schematic diagram of the frame adhesive layer described in an embodiment of this application;

[0059] Figure 5b This is another structural schematic diagram of the frame adhesive layer described in the embodiments of this application;

[0060] Figure 6This is another structural schematic diagram of the display device described in the embodiments of this application;

[0061] Figure 7 This is another structural schematic diagram of the display device described in the embodiments of this application;

[0062] Figure 8 This is a schematic flowchart of the manufacturing method of the display device described in the embodiments of this application;

[0063] Figure 9a This is a schematic diagram illustrating the manufacturing process of some of the sound-generating structures in the embodiments of this application;

[0064] Figure 9b This is a schematic diagram illustrating the manufacturing process of another part of the sound-generating structure in an embodiment of this application;

[0065] Figure 10a This is a schematic diagram illustrating another manufacturing process of some of the sound-generating structures in the embodiments of this application;

[0066] Figure 10b This is a schematic diagram illustrating another manufacturing process of a sound-generating structure in another embodiment of this application. Detailed Implementation

[0067] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with specific embodiments and the accompanying drawings.

[0068] It should be noted that, unless otherwise defined, the technical or scientific terms used in the embodiments of this application should have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms "first," "second," and similar terms used in the embodiments of this application do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are only used to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0069] Directional audio transmission technology modulates an audio signal with an ultrasonic carrier signal, which is then transmitted into the air by a directional transducer. Utilizing the strong directional propagation of ultrasound in the air and its nonlinear acoustic effects, the audio signal is demodulated after propagating a certain distance, forming a highly directional audible sound signal, thereby achieving the effect of directional propagation of the audio signal.

[0070] like Figure 1 As shown, a first polarizer (upper polarizer) 1' is provided on the light-emitting surface of the display panel 2, and a second polarizer (lower polarizer) 3 can be provided on the backlight surface of the display panel. The sound-generating structure 4' is externally mounted on the side of the second polarizer 3' away from the display panel 2. The sound-generating structure 4' includes, from bottom to top: a glass substrate 410, a first electrode layer 401, a first metal layer 402, a first insulating layer 403, a columnar separator layer 404, a first adhesive layer 405, a second insulating layer 406, a second metal layer 407, a second electrode layer 408, and a protective layer (PET film) 5', and the protective layer 5' serves as the vibration unit of the sound-generating structure 4' to generate sound. The glass substrate 410 is made of 1.1T glass substrate.

[0071] The aforementioned display device is quite thick, which is not conducive to the overall integrity and thinness of the display device.

[0072] Based on the above reasons, this application provides a display device that integrates the sound-emitting structure 4' onto the display panel 2, so that there is no gap between the display panel 2 and the sound-emitting structure 4' caused by external mounting, and at the same time, there is no need to make a glass substrate 410, thereby reducing the thickness of the display device.

[0073] like Figure 2 As shown, the display device described in this embodiment includes a display panel 2, a sound-emitting unit 4 disposed on the light-emitting side of the display panel 2, and a vibration unit layer 5 disposed on the side of the sound-emitting unit 4 away from the display panel 2. The display panel 2 includes an array substrate, a liquid crystal layer 203, and a color filter substrate stacked sequentially. The array substrate includes a glass substrate 201 and thin-film transistors (TFTs) 202 disposed on the glass substrate 201. The color filter substrate includes a color filter layer 204 and an upper glass substrate 205 of the color filter substrate. The sound-generating unit 4 includes a first electrode layer 401, a first metal layer 402, a first insulating layer 403, a columnar spacer layer 404, a second insulating layer 406, a second metal layer 407, and a second electrode layer 408, which are sequentially stacked along the light-emitting direction of the display panel 2. The columnar spacer layer 404 forms an ultrasonic vibration chamber. The first electrode layer 401 and the second electrode layer 408 are the electrodes of the sound-generating unit 4, which can be ITO film layers. Signal voltage is transmitted through the first electrode layer 401 and the second electrode layer 408, thereby applying voltage to the ultrasonic vibration chamber of the columnar spacer layer 404 to control the vibration of the ultrasonic vibration chamber. The vibration is transmitted to the vibration unit layer 5, and directional vibration is generated through the vibration unit layer 5.

[0074] In this embodiment, the film layer structure of the sound-emitting unit 4 is directly fabricated on the display panel 2. That is, the first electrode layer 401, the first metal layer 402, the first insulating layer 403, the columnar spacer layer 404, the second insulating layer 406, the second metal layer 407, and the second electrode layer 408 of the sound-emitting unit 4 are directly formed on the upper glass substrate 205 of the display panel 2, thereby integrating the sound-emitting unit 4 onto the display panel 2. This saves the glass substrate 410 formed by the 1.1T glass substrate, thus reducing the thickness of the display device. At the same time, since the film layer structure of the sound-emitting unit 4 is directly fabricated on the display panel 2, there are no gaps caused by external mounting, thus further reducing the thickness of the display device.

[0075] In some embodiments, such as Figure 3a , Figure 3c As shown, the first metal layer 402 includes a first metal frame 4021, a first electrode lead 4022, and a second electrode lead 4023 formed on the first electrode layer 401. The first metal frame 4021 is formed at the edge of the first electrode layer 401. The first electrode lead 4022 and the second electrode lead 4023 are both formed at one end of the first electrode layer 401 and are respectively connected to an external electrode. Simultaneously, the first electrode lead 4022 is connected to the first metal frame 4021, thereby allowing signals transmitted from the external electrode to be quickly transmitted to the entire first electrode layer 401 through the first metal frame 4021, while ensuring the transmittance of the display device. The second electrode lead 4023 is formed at one end of the first electrode layer 401 and is electrically insulated from the first metal frame 4021.

[0076] like Figure 3a , 3b As shown, the first electrode lead 4022 and the second electrode lead 4023 are both disposed at one end of the first electrode layer 401, and the second electrode lead 4023 is disposed in the middle and electrically insulated from the first metal frame 4021. The two first electrode leads 4022 are respectively disposed on both sides of the second electrode lead 4023 and connected to the first metal frame 4021, thereby realizing the integration of the bonding electrode on one side.

[0077] like Figure 3c As shown in Figures 3 and 3e, the first electrode lead 4022 is disposed in the middle and connected to the first metal frame 4021, and two second electrode leads 4023 are respectively disposed on both sides of the first electrode lead 4022 and electrically insulated from the first metal frame 4021, thereby realizing the integration of the bonding electrode on one side.

[0078] like Figure 4aAs shown, the second metal layer 407 includes a second metal frame 4071, which is formed on the edge of the second electrode layer 408 and connected to the second electrode lead 4023. This allows the signal transmitted from the external electrode to be quickly transmitted to the entire second electrode layer 408 through the second metal frame 4071, while ensuring the transmittance of the display device.

[0079] In the above embodiments, the first electrode lead 4022 and the second electrode lead 4023 are both formed on one end of the first electrode layer 401, thereby integrating the bonding electrode for connecting with the external electrode on one side. On the one hand, this facilitates the fabrication of the first electrode lead 4022 and the second electrode lead 4023 and reduces the difficulty of the process; on the other hand, integrating the first electrode lead 4022 and the second electrode lead 4023 on one side and setting them in the same layer can avoid the increase in the thickness of the display device caused by setting the two electrode leads separately, thereby reducing the thickness of the display device.

[0080] Optionally, the display device further includes an electrical connection unit 4024 disposed on the second electrode lead 4023, through which the second electrode lead 4023 is connected to the second metal frame 4071. In this embodiment, since the first metal layer 402 and the second metal layer 407 also include a first insulating layer 403, a columnar separator layer 404 and a second insulating layer 406, and the first electrode layer 401 and the second electrode layer 408 need to be electrically insulated, an electrical connection unit 4024 needs to be formed between the second electrode lead 4023 and the second metal frame 4071 to achieve electrical connection between the second metal layer 407 and the second electrode lead 4023.

[0081] Optional, such as Figure 3e As shown, the extension portion of the electrical connection unit 4024 is electrically insulated above the first metal frame 4021, allowing the extension portion of the electrical connection unit 4024 to connect with the second metal frame 4071, thereby enabling better transmission of the electrical signal on the second electrode lead 4023 to the second metal frame 4071. Optionally, the extension portion of the electrical connection unit 4024 may include a gold ball to facilitate connection with the second metal frame 4071. Non-conductive adhesive 4026 may be disposed above the first electrode lead 4022 to prevent electrical connection between the first electrode lead 4022 and the second metal frame 4071.

[0082] Optionally, when higher precision is required, the thickness of the first metal layer 402 and the second metal layer 407 can be less than or equal to 3 μm, and the width of the first metal frame 4021 and the second metal frame 4071 can be less than 4 mm. In this embodiment, LCD manufacturing equipment can be used to fabricate the first metal frame 4021 and the second metal frame 4071 using a patterning process with a photomask. This allows the width of the first metal frame 4021 and the second metal frame 4071 to be less than 4 mm, and the thickness of the first metal layer 402 and the second metal layer 407 to be less than or equal to 3 μm. Compared to the metal frames with a width greater than 10 mm and a thickness greater than 10 μm produced by screen printing in the prior art, this embodiment can achieve the requirement of a narrow bezel while maintaining the same resistance of the first metal layer 402 and the second metal layer 407, and can reduce the overall thickness of the display device.

[0083] In some embodiments, the display panel 2 includes a plurality of pixel units. For example... Figure 3b , Figure 3d , Figure 3e , Figure 3f As shown, the first metal layer 402 further includes a first metal grid line 4025 formed within and connected to the first metal frame 4021. The first metal grid line 4025 divides the first metal layer 402 into a plurality of first metal grids, and each first metal grid is correspondingly set to one or more pixel units of the display panel 2.

[0084] like Figure 4b As shown, the second metal layer 407 further includes a second metal grid line 4072 formed within and connected to the second metal frame 4071. The second metal grid line 4072 divides the second metal layer 407 into a plurality of second metal grids, and each second metal grid is correspondingly set to one or more pixel units of the display panel 2.

[0085] Optionally, in the above embodiments, a first metal grid line 4025 and a second metal grid line 4072 can be formed on both the first metal layer 402 and the second metal grid line 4072, or the first metal grid line 4025 can be formed only on the first metal layer 402 without forming the second metal grid line 4072 to increase the transmittance of the display device. The display can be manufactured using LCD manufacturing equipment, and the first metal grid line 4025 and / or the second metal grid line 4072 can be formed using a patterning process with a photomask. The arrangement of the first metal grid line 4025 and / or the second metal grid line 4072 can effectively reduce the overall resistance. As shown in the table below, compared to the metal frame manufactured using screen printing in the prior art, with the same 1-6Ω resistance, the bezel can be narrower, thus achieving a narrow bezel effect.

[0086]

[0087] In some embodiments, the display panel 2 includes a color filter substrate, which includes a black matrix; the orthographic projections of the first metal grid line 4025 and the second metal grid line 4072 on the color filter substrate are located within the black matrix, thereby preventing the first metal grid line 4025 and the second metal grid line 4072 from blocking light and reducing the transmittance of the display device. In some embodiments, the first metal grid line 4025 and the second metal grid line 4072 may not be placed above the black matrix.

[0088] Optionally, the first metal grid line 4025 can be parallel to each side of the first metal frame 4021, or it can be at a certain angle to each side of the first metal frame 4021; the first metal grid line 4025 can be a straight line or a non-straight line. Correspondingly, the second metal grid line 4072 can be parallel to each side of the second metal frame 4071, or it can be at a certain angle to each side of the second metal frame 4071; the second metal grid line 4072 can be a straight line or a non-straight line.

[0089] In some embodiments, the orthographic projections of the first metal frame 4021 and the first metal mesh line 4025 on the display panel 2 are located within the orthographic projection of the first insulating layer 403 on the display panel 2. That is, the first insulating layer 403 can achieve electrical insulation between the first metal frame 4021 and the first metal mesh line 4025, thereby preventing a short circuit in the sound unit caused by electrical connection between the first electrode layer 401 and the second electrode layer 408. The orthographic projection of the second electrode lead 4023 on the display panel 2 coincides with the orthographic projection of the first insulating layer 403 on the display panel 2. The orthographic projections on the display panel 2 do not overlap. Since the second electrode lead 4023 needs to be electrically connected to the second metal frame 4071, the first insulating layer 403 does not need to cover the second electrode lead 4023. At the same time, the orthographic projection of the electrical connection unit 4024 on the display panel 2 does not overlap with the orthographic projection of the first insulating layer 403 on the display panel 2. Since the second electrode lead 4023 needs to be electrically connected to the second metal frame 4071 through the electrical connection unit 4024, the first insulating layer 403 also does not need to cover the electrical connection unit 4024.

[0090] The orthographic projections of the first electrode lead 4022 and the second electrode lead 4023 on the display panel 2 do not overlap with the orthographic projection of the second insulating layer 406 on the display panel 2; the orthographic projections of the second metal frame 4071 and the second metal mesh line 4072 on the display panel 2 are located within the orthographic projection of the second insulating layer 406 on the display panel 2, that is, the second insulating layer 406 can achieve electrical insulation between the second metal frame 4071 and the second metal mesh line 4072, thereby avoiding short circuit of the sound unit caused by electrical connection between the first electrode layer 401 and the second electrode layer 408.

[0091] The first insulating layer 403 protects the first electrode layer 401, and the second insulating layer 406 protects the second electrode layer 408 and increases the resistance to breakdown.

[0092] In some embodiments, the columnar spacer layer 404 includes a plurality of columnar spacers arranged in an array, with sound-emitting sub-units formed between the columnar spacers, for example, one sound-emitting sub-unit is formed between every four columnar spacers. Each sound-emitting sub-unit corresponds to one or more pixel units of the display panel 2. The shape, size, spacing, height, etc., of the columnar spacers can be determined by simulation calculations to obtain suitable parameters. The material of the columnar spacers can be a low-temperature organic film, such as resin-based organic materials. The columnar spacers can be fabricated using a low-temperature organic film photomask (PS) process.

[0093] Optionally, the display panel includes a color filter substrate, which includes a black matrix; the orthographic projection of the columnar spacer on the color filter substrate is located within the black matrix, thereby preventing the columnar spacer from blocking light and reducing the transmittance of the display device. Optionally, the columnar spacer can also be disposed at any position.

[0094] Optionally, the orthographic projection of the columnar spacer on the display panel 2 at least partially overlaps with the orthographic projection of the first metal grid line 4025 and / or the second metal grid line 4072 on the display panel 2, that is, the columnar spacer is also disposed on the black matrix of the color filter substrate, thereby improving the transmittance of the display device.

[0095] In some embodiments, the display device further includes a frame adhesive layer 405, which is disposed between the first insulating layer 403 and the second insulating layer 406 to bond the first insulating layer 403 and the second insulating layer 406, thereby achieving the bonding of the two parts of the sound-emitting unit through the frame adhesive layer 405.

[0096] like Figure 5a As shown, the frame adhesive layer 405 includes multiple frame adhesive units 4051, and an air circulation channel is provided between two adjacent frame adhesive units 4051. This air circulation channel allows air to enter the vibration chamber between the columnar spacers, thereby achieving sound generation. Each air circulation channel has a blocking unit 4052 parallel to the frame adhesive unit 4051 on the side closest to the columnar spacer, and the width of the blocking unit 4052 is greater than the width of the air circulation channel, thereby preventing dust from falling into the vibration chamber.

[0097] Optional, such as Figure 5b As shown, the end of the frame adhesive unit 4051 facing the blocking unit 4052 is provided with a first extension 4053, and the end of the blocking unit 4052 facing the frame adhesive unit 4051 is provided with a second extension 4054. Two second extensions 4054 are provided between two first extensions 4053 on the same frame adhesive unit 4051, and the two second extensions 4054 are provided on different blocking units 4052. Similarly, two first extensions 4053 are provided between two second extensions 4052 on the same blocking unit 4052, and the two first extensions 4053 are provided on different frame adhesive units 4051. This design ensures that when air enters the vibration chamber through the airflow channel, it must pass through an S-shaped channel to successfully enter, further preventing dust from falling in and affecting the sound production effect.

[0098] In some embodiments, such as Figure 6As shown, the vibration unit layer 5 includes a first polarizer 1, and a second polarizer 3 is disposed on the backlight surface of the display panel 2. The first polarizer 1 includes a protective layer 301, a polarizing film 302, and a surface coating 303, which are sequentially stacked on the second electrode layer 408 along the light emission direction of the display panel 2. The material of the protective layer 301 may include cycloolefin polymer (COP) or triacetyl cellulose (TAC), the material of the polarizer 302 may include polyvinyl alcohol (PVA), and the material of the surface coating 303 may include triacetyl cellulose (TAC) and a hard coating (HC). The second polarizer 3 includes a second adhesive layer (PSA) 104, a second protective layer 103, a second polarizing film 102, and a second coating layer 101, which are sequentially stacked along the backlight surface of the display panel 2. The material of the second protective layer 103 may include triacetyl cellulose (TAC), the material of the second polarizing film 102 may include polyvinyl alcohol (PVA), and the material of the second coating layer 101 may include triacetyl cellulose (TAC) and a hard coating (HC). In this embodiment, the first polarizer 1 serves both as a polarizer and a vibrator; therefore, selecting an ultra-thin structure for the first polarizer 1 can achieve a good vibration and sound generation effect.

[0099] In other embodiments, such as Figure 7As shown, the vibration unit layer 5 includes a protective layer (PET) 409, and a third polarizer 6 is disposed between the display panel 2 and the sound-emitting unit 4. A second polarizer 3 is disposed on the backlight surface of the display panel 2. The third polarizer 6 includes a first adhesive layer 604, a first protective film 601, a first linear polarizing film 602, and a second protective film 603, sequentially stacked on the upper glass substrate 205 of the color filter substrate along a light-emitting direction away from the display panel 2. The material of the first protective film 601 may include cycloolefin polymer (COP) or triacetyl cellulose (TAC), the material of the first linear polarizing film 602 may include polyvinyl alcohol (PVA), and the material of the second protective film 603 may include triacetyl cellulose (TAC) and a hard coating (HC). The second polarizer 3 includes a second adhesive layer (PSA) 104, a second protective layer 103, a second polarizing film 102, and a second coating layer 101, which are sequentially stacked along the backlight surface of the display panel 2. The material of the second protective layer 103 may include triacetyl cellulose (TAC), the material of the second polarizing film 102 may include polyvinyl alcohol (PVA), and the material of the second coating layer 101 may include triacetyl cellulose (TAC) and a hard coating (HC). In this embodiment, the protective layer (PET) 409 serves as the vibrating unit of the sound-generating unit 4.

[0100] This application also provides a method for manufacturing a display device, such as... Figure 8 As shown, the manufacturing method includes:

[0101] Step S101: Provide a display panel and a vibration unit layer.

[0102] In step S102, a first electrode layer, a first metal layer, and a first insulating layer are sequentially formed on the light-emitting side of the display panel, and a second electrode layer, a second metal layer, and a second insulating layer are sequentially formed on the side of the vibration unit layer near the display panel.

[0103] Step S103: Form a columnar spacer layer on the first insulating layer or the second insulating layer.

[0104] Step S104: The first insulating layer and the second insulating layer are bonded together to form the display device.

[0105] In this embodiment, the film layer structure of the sound-emitting unit is directly fabricated on the display panel. That is, the first electrode layer, first metal layer, first insulating layer, columnar spacer layer, second insulating layer, second metal layer and second electrode layer of the sound-emitting unit are directly formed on the upper glass substrate of the display panel, thereby integrating the sound-emitting unit on the display panel. This saves the glass substrate formed by the 1.1T glass substrate, thus reducing the thickness of the display device. At the same time, since the film layer structure of the sound-emitting unit is directly fabricated on the display panel, there are no gaps caused by external mounting, which can further reduce the thickness of the display device.

[0106] In some embodiments, the manufacturing method further includes at least one of the following:

[0107] Step S201: A material film layer for forming the first electrode layer is formed on the display panel by using a photomask and a patterning process to form the pattern of the first electrode layer.

[0108] Step S202: A metal thin film is formed on the first electrode layer, and a pattern of the first metal layer is formed by using a photomask and a patterning process.

[0109] Step S203: A first insulating layer material film is formed on the first metal layer, and a pattern of the first insulating layer is formed by using a photomask and a patterning process.

[0110] Step S204: A columnar spacer material film is formed on the first insulating layer or the second insulating layer, and the pattern of the columnar spacer layer is formed by a patterning process using a photomask.

[0111] In this embodiment, one or more layers of the first electrode layer, first metal layer, first insulating layer, and columnar spacer layer are fabricated on the side of the display panel using LCD manufacturing equipment, achieving a precision of 2.5 μm, thus matching the precision of the display panel. Compared to the 150-micron precision of the screen printing process used in the prior art, this significantly improves the precision of the first metal layer and other film layers.

[0112] In some embodiments, the display panel includes a color filter substrate, and the vibration unit layer includes a first polarizer;

[0113] In step S102, a first electrode layer, a first metal layer, and a first insulating layer are sequentially formed on the light-emitting side of the display panel, as follows: Figure 9a As shown, the method includes: sequentially forming a first electrode layer, a first metal layer, and a first insulating layer on the color filter substrate. The first electrode layer, the first metal layer, and the first insulating layer can be sequentially formed on the color filter substrate using a photomask and a patterning process.

[0114] Optionally, the first electrode layer, the first metal layer, and the first insulating layer can be fabricated on the display panel after cell assembly. In this case, a low-temperature process (25°C-140°C) is required. Alternatively, the first electrode layer, the first metal layer, and the first insulating layer can be formed sequentially on the upper glass substrate of the color filter substrate first, and then the color filter substrate and the display panel assembly process can be performed sequentially. In this case, a low-temperature process is not required.

[0115] Optionally, the first electrode layer is fabricated using magnetron sputtering, with a resistance of 10–70 Ω. The first insulating layer can be fabricated using organic film coating or inorganic PVX processes; since it is applied to the display cell after cell assembly, both require low-temperature processing (temperature <120°C). The first insulating layer can be deposited using plasma-enhanced chemical vapor deposition (PCVD) to deposit the SiN. x Compared to the 10μm thick organic insulating layer produced by existing screen printing processes, the insulating layer only needs to be 6000A thick while ensuring the same resistance to 400V voltage breakdown, thus reducing the thickness of the insulating layer.

[0116] In step S102, a second electrode layer, a second metal layer, and a second insulating layer are sequentially formed on the side of the vibration unit layer near the display panel, as shown below. Figure 9b As shown, the process includes: sequentially forming a second electrode layer, a second metal layer, and a second insulating layer on the side of the first polarizer near the display panel. This can be achieved using screen printing, coating by a POL (Polymer Optical Coating System) manufacturer, or a patterning process using a photomask.

[0117] Optionally, after the first polarizer's various film layers are fabricated, the second electrode layer, the second metal layer, and the second insulating layer can be sequentially formed on the side of the first polarizer closest to the display panel. Alternatively, the second electrode layer, the second metal layer, and the second insulating layer can be first deposited on the protective layer 301 of the first polarizer to form the second electrode layer, the second metal layer, and the second insulating layer, and then composited with the polarizing film 302. The second insulating layer can be fabricated using a thin-film coating process.

[0118] Optionally, the protective layer 301 of the first polarizer 1 can be attached to the Glass using the Lami process with a low-temperature anti-tack temperature-controlled adhesive. Then, the second electrode layer, the second metal layer, and the second insulating layer can be fabricated on it using LCD equipment. Finally, the Glass can be removed by Delami and then laminated with other film materials of the first polarizer 1.

[0119] In other embodiments, a first polarizer is provided on the light-emitting side of the display panel. The first polarizer includes a first adhesive layer, a first protective film, a first linear polarizing film, and a second protective film, which are sequentially stacked along the light-emitting direction away from the display panel; the vibration unit layer includes a protective layer.

[0120] In step S102, a first electrode layer, a first metal layer, and a first insulating layer are sequentially formed on the light-emitting side of the display panel, as follows: Figure 10a , Figure 10b As shown, the method includes: providing a second protective film, forming a first electrode layer, a first metal layer and a first insulating layer sequentially on one side of the second protective film, forming a first linear polarizer, the first protective film and a first adhesive layer sequentially on the other side of the second protective film, and attaching the first adhesive layer to the display panel.

[0121] The step S102, which involves sequentially forming a second electrode layer, a second metal layer, and a second insulating layer on the side of the vibration unit layer near the display panel, includes: sequentially forming the second electrode layer, the second metal layer, and the second insulating layer on the side of the protective layer near the display panel.

[0122] In this process, a second electrode layer, a second metal layer, and a second insulating layer are fabricated on the side of the protective layer closest to the display panel using magnetron sputtering, screen printing, and coating processes. The first electrode layer, the first metal layer, and the first insulating layer are then fabricated on the second protective film using the same processes. This structure is then rolled-to-rolled with a first linear polarizer, the first protective film, and the first adhesive layer to create a special polarizer with a flexible directional sound-emitting device structure. Finally, this polarizer is attached to the color filter substrate of the display panel to form the final integrated structure. This structure utilizes the vibration of the protective layer to generate sound, avoiding damage to the PVA caused by the polarizer vibration. The roll-to-roll process allows for the creation of a special POL component with an integrated structure (possessing directional sound generation functionality), simplifying mass production processes.

[0123] In some embodiments, the display panel includes a color filter substrate, the color filter substrate including a black matrix; the columnar spacer layer includes a plurality of columnar spacers arranged in an array; the process of forming the pattern of the columnar spacer layer using a mask through a patterning process includes: forming the columnar spacers on the first insulating layer or the second insulating layer using a mask through a patterning process, such that the orthogonal projection of the columnar spacers on the color filter substrate is located within the black matrix, thereby avoiding the columnar spacers from blocking light and causing a decrease in the transmittance of the display device.

[0124] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of this application (including the claims) is limited to these examples; within the framework of this application, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of the embodiments of this application as described above, which are not provided in the details for the sake of brevity.

[0125] Additionally, to simplify the description and discussion, and to avoid obscuring the embodiments of this application, the well-known power / ground connections to integrated circuit (IC) chips and other components may or may not be shown in the provided drawings. Furthermore, the apparatus may be shown in block diagram form to avoid obscuring the embodiments of this application, and this also takes into account the fact that the details of the implementation of these block diagram apparatuses are highly dependent on the platform on which the embodiments of this application will be implemented (i.e., these details should be fully understood by those skilled in the art). While specific details (e.g., circuits) have been set forth to describe exemplary embodiments of this application, it will be apparent to those skilled in the art that the embodiments of this application can be implemented without these specific details or with variations thereof. Therefore, these descriptions should be considered illustrative rather than restrictive.

[0126] Although this application has been described in conjunction with specific embodiments thereof, many substitutions, modifications, and variations of these embodiments will be apparent to those skilled in the art from the foregoing description. For example, other memory architectures (e.g., dynamic RAM (DRAM)) may be used with the embodiments discussed.

[0127] The embodiments of this application are intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the embodiments of this application should be included within the protection scope of this application.

Claims

1. A display device, characterized in that, It includes a display panel, a sound-emitting unit disposed on the light-emitting side of the display panel, and a vibration unit layer disposed on the side of the sound-emitting unit away from the display panel; The display panel includes a color filter substrate, which includes an upper glass substrate and a black matrix. The sound-emitting unit includes a first electrode layer, a first metal layer, a first insulating layer, a columnar spacer layer, a second insulating layer, a second metal layer, and a second electrode layer, which are sequentially stacked along the light-emitting direction of the display panel, and the first electrode layer is formed on the upper glass substrate. The first metal layer includes a first metal grid line, and the second metal layer includes a second metal grid line; the orthographic projections of the first metal grid line and the second metal grid line on the color filter substrate are located within the black matrix; The columnar spacer layer includes a plurality of columnar spacers arranged in an array, and the orthographic projection of the columnar spacers on the color filter substrate is located within the black matrix.

2. The display device according to claim 1, characterized in that, The first metal layer includes a first metal frame, a first electrode lead, and a second electrode lead. The first metal frame is formed at the edge of the first electrode layer, the first electrode lead is formed at one end of the first electrode layer and connected to the first metal frame, and the second electrode lead is formed at one end of the first electrode layer and electrically insulated from the first metal frame. The second metal layer includes a second metal frame, which is connected to the second electrode lead; The first electrode lead and the second electrode lead are used to connect to external electrodes.

3. The display device according to claim 2, characterized in that, It also includes an electrical connection unit disposed on the second electrode lead, through which the second electrode lead is connected to the second metal frame.

4. The display device according to claim 2, characterized in that, The display panel includes multiple pixel units; The first metal grid line is formed within the first metal frame and connected to the first metal frame. The first metal grid line divides the first metal layer into multiple first metal grids, and each first metal grid is correspondingly set to one or more pixel units of the display panel. And / or, The second metal grid line is formed within and connected to the second metal frame. The second metal grid line divides the second metal layer into multiple second metal grids, and each second metal grid corresponds to one or more pixel units of the display panel.

5. The display device according to claim 4, characterized in that, The orthographic projections of the first metal frame and the first metal mesh line on the display panel are located within the orthographic projection of the first insulating layer on the display panel, and the orthographic projections of the second electrode lead on the display panel do not overlap with the orthographic projections of the first insulating layer on the display panel; The orthographic projections of the first electrode lead and the second electrode lead on the display panel do not overlap with the orthographic projection of the second insulating layer on the display panel; the orthographic projections of the second metal frame and the second metal grid line on the display panel are located within the orthographic projection of the second insulating layer on the display panel.

6. The display device according to claim 1, characterized in that, A sound-emitting sub-unit is formed between multiple columnar spacers, and each of the sound-emitting sub-units is configured to correspond to one or more pixel units of the display panel.

7. The display device according to claim 6, characterized in that, Also includes: A frame adhesive layer is disposed between the first insulating layer and the second insulating layer to bond the first insulating layer and the second insulating layer; The frame adhesive layer includes multiple frame adhesive units, and an air circulation channel is provided between two adjacent frame adhesive units. Each air circulation channel has a blocking unit parallel to the frame adhesive unit on the side near the columnar spacer, and the width of the blocking unit is greater than the width of the air circulation channel.

8. The display device according to claim 7, characterized in that, The end of the frame adhesive unit facing the blocking unit is provided with a first extension. The end of the blocking unit facing the frame adhesive unit is provided with a second extension. Two second extensions are provided between two first extensions disposed on the same frame adhesive unit, and the two second extensions are disposed on different blocking units; two first extensions are provided between two second extensions disposed on the same blocking unit, and the two first extensions are disposed on different frame adhesive units.

9. The display device according to any one of claims 1-8, characterized in that, The vibration unit layer includes a first polarizer, and the backlight surface of the display panel is provided with a second polarizer; or, The vibration unit layer includes a protective layer, and a third polarizer is disposed between the display panel and the sound-generating unit, and a second polarizer is disposed on the backlight surface of the display panel.

10. A method for manufacturing a display device, characterized in that, include: A display panel and a vibration unit layer are provided, wherein the display panel includes a color filter substrate, and the color filter substrate includes an upper glass substrate and a black matrix; A first electrode layer, a first metal layer, and a first insulating layer are sequentially formed on the light-emitting side of the display panel. A second electrode layer, a second metal layer, and a second insulating layer are sequentially formed on the side of the vibration unit layer near the display panel. The first electrode layer is formed on the upper glass substrate. The first metal layer includes a first metal grid line, and the second metal layer includes a second metal grid line. The orthogonal projections of the first metal grid line and the second metal grid line on the color filter substrate are located within the black matrix. A columnar spacer layer is formed on the first insulating layer or the second insulating layer. The columnar spacer layer includes a plurality of columnar spacers arranged in an array. The orthogonal projection of the columnar spacers on the color filter substrate is located within the black matrix. The first insulating layer and the second insulating layer are bonded together to form the display device.

11. The manufacturing method according to claim 10, characterized in that, It also includes at least one of the following: A material film layer for forming the first electrode layer is formed on the display panel, and the pattern of the first electrode layer is formed by a patterning process using a photomask. A metal thin film is formed on the first electrode layer, and a pattern of the first metal layer is formed by a patterning process using a photomask. A thin film of a first insulating layer material is formed on the first metal layer, and a pattern of the first insulating layer is formed by using a photomask and a patterning process. A columnar spacer material film is formed on the first insulating layer or the second insulating layer, and the pattern of the columnar spacer layer is formed by a patterning process using a photomask.

12. The manufacturing method according to claim 11, characterized in that, The vibration unit layer includes a first polarizer; The first electrode layer, the first metal layer, and the first insulating layer are sequentially formed on the light-emitting side of the display panel, including: The first electrode layer, the first metal layer, and the first insulating layer are sequentially formed on the color filter substrate; The second electrode layer, the second metal layer, and the second insulating layer are sequentially formed on the side of the vibration unit layer near the display panel, including: The second electrode layer, the second metal layer, and the second insulating layer are sequentially formed on the side of the first polarizer near the display panel.

13. The manufacturing method according to claim 11, characterized in that, A third polarizer is provided on the light-emitting side of the display panel. The third polarizer includes a first adhesive layer, a first protective film, a first linear polarizer, and a second protective film, which are sequentially stacked along the light-emitting direction away from the display panel. The vibration unit layer includes a protective layer. The first electrode layer, the first metal layer, and the first insulating layer are sequentially formed on the light-emitting side of the display panel, including: A second protective film is provided, on one side of the second protective film the first electrode layer, the first metal layer and the first insulating layer are formed sequentially, and on the other side of the second protective film the first linear polarizer, the first protective film and the first adhesive layer are formed sequentially, and the first adhesive layer is bonded to the display panel; The second electrode layer, the second metal layer, and the second insulating layer are sequentially formed on the side of the vibration unit layer near the display panel, including: The second electrode layer, the second metal layer, and the second insulating layer are sequentially formed on the side of the protective layer near the display panel.

14. The manufacturing method according to claim 11, characterized in that, The process of forming the pattern of the columnar spacer layer using a photomask through a patterning process includes: The columnar spacers are formed on the first insulating layer or the second insulating layer using a photomask patterning process, such that the orthogonal projection of the columnar spacers on the color filter substrate is located within the black matrix.

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