Display devices and their manufacturing methods

Abstract

A display device and a method of manufacturing the same are provided. The method includes: preparing a panel having a panel layer for displaying an image, a first protective film located on a first surface of the panel layer using a first adhesive layer, and a second protective film located on a second surface of the panel layer using a second adhesive layer; cutting the panel on a platform to a predetermined depth along a closed-curve cutting line, the predetermined depth extending from the second protective film to at least a portion of the first adhesive layer; and separating a first portion of the panel located inside the closed-curve cutting line from a second portion of the panel located outside the closed-curve cutting line, such that the second portion and the entire first protective film are removed simultaneously according to a first boundary formed by the cutting line and a second boundary between the panel layer and the first protective film.

Description

[0001] This application is a divisional application of the patent application filed on September 30, 2017, with application number 201710924407.7 and title "Display Device and Method of Manufacturing Thereof". Technical Field

[0002] One or more embodiments relate to display devices and methods of manufacturing the same, and more specifically, to flexible display devices and methods of manufacturing the same with respect to improving the process of cutting the edges of a flexible panel to cut the flexible panel into a desired shape. Background Technology

[0003] Typically, flexible display devices are flexible by forming a device layer for generating images on a flexible substrate, and have the advantage that they can be bent if needed. When manufacturing flexible display devices, the edges of the flexible panel are cut to desired specifications and shapes, such as rounded corners. Summary of the Invention

[0004] One or more embodiments include a display device and a method of manufacturing thereof that relates to improving the process of cutting the edges of a flexible panel to cut the panel into a desired shape.

[0005] According to one or more embodiments, a method of manufacturing a display device includes: preparing a panel such that the panel includes a panel layer for displaying an image, a first protective film attached to a first surface of the panel layer by a first adhesive layer, and a second protective film attached to a second surface of the panel layer by a second adhesive layer; placing the panel on a platform such that the platform faces the first protective film; cutting the panel on the platform to a predetermined depth along a closed-curve cutting line, the predetermined depth extending from the second protective film to at least a portion of the first adhesive layer; and separating a first portion of the panel located inside the closed-curve cutting line from a second portion of the panel located outside the closed-curve cutting line, such that the second portion and the entire first protective film are removed simultaneously according to a first boundary formed by the cutting line and a second boundary between the panel layer and the first protective film.

[0006] The inner region of the closed curve cutting line may include a display unit on which an image is displayed, and the outer region of the closed curve cutting line may include a dummy unit as a non-display area.

[0007] The cutting process of the flexible panel may include irradiating a laser along a closed curve cutting line from one side of the second protective film.

[0008] The cutting groove formed by the laser can have a space that gradually decreases from the second protective film toward the first adhesive layer.

[0009] Lasers can include one of the following: CO2 lasers, green lasers, infrared lasers, and ultraviolet lasers.

[0010] The setup steps for the flexible panel on the platform may include securely fixing the flexible panel to the platform.

[0011] The platform may include suction holes, and the steps for securing the flexible panel on the platform may include applying suction to the flexible panel through the suction holes to attach the flexible panel to the platform.

[0012] The method may also include forming a polarizing layer on a panel layer in the inner region of the closed curve cut line from which the first protective film is removed.

[0013] The polarizing layer may include a polarizing film that will be attached to the panel layer.

[0014] The cutting step of the flexible panel on the platform may include forming a flexible panel with an edge having an angled shape that gradually increases in width, and the step of forming a polarizing layer may include forming a polarizing layer with a straight edge perpendicular to the top surface of the panel layer.

[0015] A closed curve cutting line can be a rectangular shape with rounded corners.

[0016] A closed curve cutting line can have a rectangular shape attached to one side of a circle.

[0017] The panel layer may include organic light-emitting diodes.

[0018] According to one or more embodiments, a display device includes: a panel, including a panel layer for displaying an image; a protective film located on a first surface of the panel layer; and a polarizing layer located on a second surface of the panel layer, the first surface and the second surface facing away from each other, wherein the edge of the panel layer is inclined at a predetermined angle relative to a dashed line, the dashed line extending along the normal of the polarizing layer.

[0019] Flexible panels may include edges with a sloping shape whose width gradually increases from the protective film to the polarizing layer.

[0020] The width of a flexible panel can gradually increase from the protective film to the panel layer, and the panel layer and the polarizing layer can have the same width.

[0021] An adhesive layer can be placed between the protective film and the panel layer.

[0022] The polarizing layer may include a polarizing film that will be attached to the panel layer.

[0023] Polarizing films can be applied directly to flexible panels.

[0024] The flexible panel can have slanted edges, and the polarizing film can have straight edges perpendicular to the top surface of the panel layer. Attached Figure Description

[0025] The features will become clear to those skilled in the art by referring to the detailed description of exemplary embodiments in the accompanying drawings, in which:

[0026] Figure 1 A plan view of a flexible panel of a flexible display device, according to an example embodiment, is shown on a platform for cutting a flexible panel into a desired shape.

[0027] Figure 2 It shows along Figure 1 A sectional view taken from line II-II;

[0028] Figure 3A The illustration shows laser cutting along the cutting line according to an example embodiment. Figure 2 A cross-sectional view of the manufacturing process of the flexible panel;

[0029] Figure 3B It shows Figure 3A A perspective view of the flexible panel in the image;

[0030] Figure 3C It shows Figure 3A A magnified view of region A;

[0031] Figure 4A The image shows the removal of the flexible panel together. Figure 3A A cross-sectional view of the cut-out dummy unit and the protective film process.

[0032] Figure 4B It shows Figure 4A A perspective view of the resulting product;

[0033] Figure 5A It shows that a polarization layer is formed on it. Figure 4A A cross-sectional view of the flexible panel separated in the middle;

[0034] Figure 5B It shows Figure 5A A perspective view of the resulting product;

[0035] Figure 5C It shows Figure 5A Enlarged sectional view of the two edges;

[0036] Figure 5D It shows Figure 5C An enlarged sectional view of region B in the diagram;

[0037] Figure 6 It shows Figure 1 A plan view illustrating the modification of the cutting line; and

[0038] Figure 7 It shows Figure 1 A cross-sectional view of the internal structure of the flexible panel display unit. Detailed Implementation

[0039] Exemplary embodiments will now be described more fully below with reference to the accompanying drawings; however, these exemplary embodiments may be implemented in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey exemplary implementation methods to those skilled in the art.

[0040] In the accompanying drawings, the dimensions of layers and regions may be exaggerated for clarity. It will also be understood that when a layer or element is referred to as "on" another layer or substrate, the layer or element may be directly on said other layer or substrate, or there may be intermediate layers. Furthermore, it will be understood that when a layer is referred to as "between two layers," the layer may be the only layer between said two layers, or there may be one or more intermediate layers. The same reference numerals always denote the same elements.

[0041] In the following embodiments, the singular form includes the plural form unless the context clearly indicates otherwise. Furthermore, in the following embodiments, it will be understood that when the term "comprising" and / or variations thereof are used in this specification, it indicates the presence of the stated feature and / or component, but does not exclude the presence or addition of one or more other features and / or components, and / or groups thereof.

[0042] When certain embodiments can be implemented differently, the specific process sequence can be performed in a different order than that described. For example, two consecutively described processes can be performed substantially simultaneously or in the reverse order of their description.

[0043] Figure 1 This is a plan view of the flexible panel 100 of a flexible display device located on a platform 200 for cutting the flexible panel 100 into a desired shape, according to an example embodiment. Figure 2 It is along Figure 1 The sectional view taken from line II-II.

[0044] Typically, a flexible display device may have a structure including a flexible panel 100 that is flexible and a housing supporting the flexible panel 100. Here, the process of cutting the edges of the flexible panel 100 into the desired size and shape will be described.

[0045] Reference Figure 1Suppose that the flexible panel 100 on the platform 200 is cut along a closed curve cutting line L (i.e., a closed curve cutting line L) that includes a rectangular shape with rounded corners. The area outside the closed curve cutting line L that will be cut off can be a dummy unit 100b, i.e., an area that is a non-display area, and the remaining area inside the closed curve cutting line L can be a display unit 100a, i.e., the desired product.

[0046] Reference Figure 2 For the cutting operation, the flexible panel 100 is fixed to the platform 200. For this purpose, the platform 200 includes a suction port 201 connected to a suction pump 202 (e.g., a vacuum pump). Therefore, when suction is applied to the suction port 201 by operating the suction pump 202, the flexible panel 100 adheres to and is fixed to the platform 200 due to negative pressure.

[0047] like Figure 2 As shown, the flexible panel 100 may include a panel layer 140 on which an image is generated, and a first protective film 110 and a second protective film 120 on respective back surfaces of the panel layer 140. The first protective film 110 and the second protective film 120 are attached to the back surfaces of the panel layer 140 using a first adhesive layer 131 and a second adhesive layer 132, respectively. In other words, the first adhesive layer 131 is located between the first protective film 110 and the panel layer 140, and the second adhesive layer 132 is located between the second protective film 120 and the panel layer 140.

[0048] When the flexible panel 100 is fixed to the platform 200, the first protective film 110 is positioned facing the platform 200 and is attached directly to the platform 200, for example, and the second protective film 120 can define the outermost upper surface of the flexible panel 100. Therefore, as will be described in more detail below, when the flexible panel 100 is cut, for example using a laser, the cut is performed on the side of the second protective film 120 that is opposite to the first protective film 110.

[0049] The following describes in detail the method for manufacturing the flexible panel 100, including the cutting process. Before describing the manufacturing method, please refer to... Figure 7 Describe the internal structure of panel layer 140.

[0050] Reference Figure 7The panel layer 140 may include a thin-film transistor (TFT) 141 and an organic light-emitting diode 142. Specifically, an active layer 141f may be formed on a buffer layer 141a located on a flexible substrate 140a, and the active layer 141f may include source and drain regions thereon highly doped with N-type or P-type dopants. The active layer 141f may include an oxide semiconductor. For example, the oxide semiconductor may include, for example, metals and oxides of group 12, 13, and 14 Zn, In, Ga, Sn, Cd, Ge, or Hf. For example, the active layer 141f may include GIZO[(In₂O₃)] a (Ga2O3) b (ZnO) c (where a, b, and c are integers satisfying a≥0, b≥0, and c>0, respectively). The gate electrode 141g can be formed above the active layer 141f, and the gate insulating film 141b is placed between the gate electrode 141g and the active layer 141f. The source electrode 141h and drain electrode 141i are formed above the active layer 141f. The interlayer insulating film 141c is formed between the gate electrode 141g and the source electrode 141h and drain electrode 141i. The passivation film 141d can be formed between the source electrode 141h and drain electrode 141i and the anode 142a of the organic light-emitting diode 142.

[0051] An insulating planarization film 141e can be formed on the anode 142a, and after a predetermined opening 142d is formed in the insulating planarization film 141e, an organic light-emitting diode 142 can be formed in the insulating planarization film 141e. The insulating planarization film 141e may include, for example, acrylic.

[0052] Organic light-emitting diode 142 displays predetermined image information by emitting red, green, and blue light. Organic light-emitting diode 142 may include an anode 142a connected to the drain electrode 141i of TFT 141 to receive positive power from the drain electrode 141i of TFT 141, a cathode 142c covering all pixels and supplying negative power to the entire pixel, and an emitting layer 142b located between the anode 142a and the cathode 142c and emitting light. Hole injection layer (HIL), hole transport layer (HTL), electron transport layer (ETL), and electron injection layer (EIL) may be stacked adjacent to emitting layer 142b.

[0053] For reference, each pixel may include an emitting layer 142b, and three pixels capable of emitting red, green, and blue light respectively can form a unit pixel. Furthermore, the emitting layer 142b can be commonly formed over all pixel areas regardless of the pixel's position. In this case, the emitting layer 142b can be formed by vertically stacking or combining layers of light-emitting materials including those emitting red, green, and blue light. If white light is emitted, combinations of other light colors are also possible. Additionally, a color conversion layer or color filter may be included to convert the emitted white light into a predetermined color.

[0054] The emitter layer 142b is susceptible to moisture. Therefore, the emitter layer 142b can be protected by forming a thin film encapsulation layer on the cathode 142c. The thin film encapsulation layer can be formed by alternately stacking organic and inorganic films.

[0055] The process of cutting the edge of the flexible panel 100 having panel layer 140 can be performed as follows.

[0056] First, such as Figure 3A and Figure 3B As shown, the flexible panel 100 is fixed to the platform 200 by suction, for example, by adsorbing the flexible panel 100 onto the platform 200, and the upper surface 120a of the second protective film 120 defines the outermost upper surface of the flexible panel 100. Next, while moving the laser irradiator 300 along the closed curve cutting line L, a laser is irradiated onto one side of the second protective film 120 of the flexible panel 100. That is, as... Figure 3B As shown, while the laser irradiator 300 moves along the closed curve cutting line L, the laser is continuously irradiated onto the upper surface 120a of the second protective film 120.

[0057] Then, as Figure 3A and Figure 3C As shown, because the laser irradiates the second protective film 120, a cutting groove 101 can be formed in the flexible panel 100 along the closed curve cutting line L. At this time, the intensity of the laser is controlled, for example, adjusted so that the depth of the cutting groove 101 is not deeper than the depth of the lower surface of the first adhesive layer 131 (e.g., from the upper surface 120a of the second protective film 120). For example, as... Figure 3C As shown, the cutting groove 101 extends continuously through the second protective film 120, the second adhesive layer 132, and the panel layer 140, and at least partially through the first adhesive layer 131, without reaching the first protective film 110.

[0058] As will be referred to below Figures 4A to 4BAs discussed in detail, because the first protective film 110 can be removed together with the dummy unit 100b (i.e., the portion of the flexible panel 100 located outside the closed curve cutting line L), the cutting groove 101 does not reach the first protective film 110. Since the cutting groove 101 does not extend into the first protective film 110, the operating time of the laser irradiator 300 is minimized; that is, the risk of generating contaminants is reduced by eliminating the time spent cutting the first protective film 110. Furthermore, the risk of damage to the platform 200 located on the other side of the first protective film 110 is prevented or substantially minimized.

[0059] Return to reference Figure 3C The cutting groove 101 formed by the laser can have a width that gradually decreases from the outside to the inside. For example, the width of the cutting groove 101 in the second protective film 120 is greater than the width of the cutting groove 101 in the panel layer 140. For example, the laser can be any one of a CO2 laser, a green laser, an infrared laser, and an ultraviolet laser.

[0060] Next, as Figures 4A to 4B As shown, after the cutting groove 101 is formed along the closed curve cutting line L, the display unit 100a (i.e., the portion inside the closed curve cutting line L) and the dummy unit 100b (the portion outside the closed curve cutting line L) are separated from each other. That is, after the flexible panel 100 is cut along the closed curve cutting line L in the desired shape, the unwanted outer edges are separated, for example, the unwanted outer edges are removed.

[0061] At this time, as Figure 4A and Figure 4B As shown, the first protective film 110 of the display unit 100a is separated simultaneously with the dummy unit 100b. That is, since the cutting groove 101 is formed by laser cutting, the display unit 100a inside the closed curve cutting line L and the dummy unit 100b outside the closed curve cutting line L are connected to each other only through the first protective film 110. Therefore, when the first protective film 110 is removed (e.g., pulled apart), the dummy unit 100b outside the closed curve cutting line L can also be removed (e.g., pulled apart) together with the first protective film 110. Thus, the dummy unit 100b and the first protective film 110 are removed simultaneously in a single process.

[0062] Next, as Figure 5A and Figure 5BAs shown, a polarizing layer 150 is formed on the panel layer 140 after the first protective film 110 has been removed. For example, the polarizing layer 150 can be attached to the surface of the panel layer 140 containing the residue of the first adhesive layer 131. The polarizing layer 150 can be formed, for example, by attaching a polarizing film to the panel layer 140. When the display unit 100a of the flexible panel 100 is mounted on the housing, the manufacturing of the flexible display device is completed.

[0063] like Figure 5C As shown, when the two edges of the flexible panel 100 on which the polarization layer 150 is formed are magnified, the flexible panel 100 has an inclined structure in which the width of the flexible panel 100 gradually increases from the second protective film 120 toward the polarization layer 150. This is because the cutting groove 101 has a shape in which its space gradually decreases from the second protective film 120 due to laser cutting. Therefore, after removing the dummy unit 100b, the edges of the flexible panel 100 have such... Figure 5C The inclined shape is depicted in the figure. Therefore, the width W1 of the polarizing layer 150 is greater than the width W2 of the second protective film 120. In detail, an inclined shape is formed from the second protective film 120 to the panel layer 140, wherein the cutting groove 101 is formed by laser, and the polarizing layer 150 has the same dimensions as the panel layer 140.

[0064] In other words, such as Figure 5D As shown, the inclined structure of the flexible panel 100 gradually increases, for example, along an angle θ from the second protective film 120 to the polarizing layer 150. Specifically, as the width of the flexible panel 100 gradually increases from the second protective film 120 to the polarizing layer 150, the distance d3 (i.e., the distance between the edge of the second protective film 120 and the dashed line I) is greater than the distance d2 (i.e., the distance between the edge of the second adhesive layer 132 and the dashed line I). Similarly, the distance d2 (i.e., the distance between the edge of the second adhesive layer 132 and the dashed line I) is greater than the distance d1 (i.e., the distance between the edge of the panel layer 140 and the dashed line I). The edges of the second protective film 120, the second adhesive layer 132, and the panel layer 140 facing the dashed line I are collinear; therefore, the angle θ is limited between the dashed line I and the collinear edge. The dashed line I is a dashed line extending along the normal of the polarizing layer 150 at the edge of the polarizing layer 150; that is, the distance d0 between the dashed line I and the edge of the polarizing layer 150 is zero. For example, the dashed line I can extend from the center of the bottom of the cutting groove 101.

[0065] When a flexible display device is manufactured using the method described above, cutting of the platform 200 on which the flexible panel 100 is disposed can be prevented. That is, if a cutting operation is performed using a laser to form a cutting groove through the entire thickness of the flexible panel, for example from the second protective film to the first protective film, the cutting line may have been formed in the platform supporting the flexible panel, for example along a closed curve cutting line L, thereby damaging the platform.

[0066] However, in the method according to the current embodiment described above, the cutting groove 101 is formed only above the first protective film 110. Therefore, the formation of cutting lines in the platform 200 is prevented, thereby preventing or substantially minimizing damage to the platform. Furthermore, since it is not necessary to prepare a dedicated platform for each product specification—that is, the same platform 200 can be used for all products regardless of specification—manufacturing costs can be minimized and production efficiency can be improved.

[0067] Furthermore, as described above, since the dummy unit 100b and the first protective film 110 can be removed simultaneously in a single process, the separation operation can be performed quickly. Therefore, when using the method according to the present embodiment, the productivity of flexible display devices can be greatly improved.

[0068] In the current exemplary embodiment of this disclosure, the closed curve cutting line L comprises a rectangular shape with rounded corners. However, this is an example and can be modified in various ways. For example, as Figure 6 As shown, the shape of the closed curve cutting line L can be a rectangle attached to one side of the circle.

[0069] Example embodiments have been disclosed herein, and although specific terminology has been used, it is used and interpreted in a general and descriptive sense only, and not for limiting purposes. In some cases, as will be apparent to those skilled in the art, features, characteristics, and / or elements described in connection with specific embodiments may be used alone or in combination with features, characteristics, and / or elements described in connection with other embodiments, unless otherwise expressly indicated at the time of filing of this application. Therefore, those skilled in the art will understand that various changes in form and detail may be made without departing from the spirit and scope of the invention as set forth in the claims.

Claims

1. A display device, the display device comprising: Panel layer, used to display images; A protective film is located on the first surface of the panel layer; as well as A polarizing layer, located on the second surface of the panel layer, displays an image on the second surface of the panel layer, wherein the first surface of the panel layer and the second surface of the panel layer face away from each other. Wherein, in a direction parallel to the first surface of the panel layer, the width of the first surface of the protective film is greater than the width of the second surface of the protective film, the width of the first surface of the panel layer is greater than the width of the first surface of the protective film, the first surface of the protective film is close to the first surface of the panel layer, and the second surface of the protective film is opposite to the first surface of the protective film.

2. The display device according to claim 1, further comprising an adhesive layer disposed between the first surface of the protective film and the first surface of the panel layer.

3. The display device according to claim 2, wherein, The width of the first surface of the adhesive layer is smaller than the width of the second surface of the adhesive layer, the first surface of the adhesive layer is close to the first surface of the protective film, and the second surface of the adhesive layer is close to the first surface of the panel layer.

4. The display device according to claim 1, wherein, The polarization layer is located directly on the panel layer.

5. The display device according to claim 1, wherein, The first surface of the polarization layer and the second surface of the polarization layer have the same width. The first surface of the polarization layer is close to the second surface of the panel layer, and the second surface of the polarization layer is opposite to the first surface of the polarization layer.

6. The display device according to claim 1, wherein, The polarizing layer includes a polarizing film attached to the panel layer.

7. The display device according to claim 1, wherein, The panel layer is a flexible layer.

8. The display device according to claim 1, wherein, The panel layer includes: Flexible substrate; At least one thin-film transistor is located on the flexible substrate; An organic light-emitting diode (OLED) is located on the flexible substrate, the OLED including a first electrode, a second electrode, and an emission layer electrically connected to the at least one thin-film transistor; and the second electrode. A thin-film encapsulation layer is located on the organic light-emitting diode, and the thin-film encapsulation layer includes at least one organic layer and at least one inorganic layer.

9. A display device, the display device comprising: Flexible substrate; At least one thin-film transistor is located on the flexible substrate; A light-emitting diode is located on the first surface of the flexible substrate; A thin-film encapsulation layer is located on the light-emitting diode, and the thin-film encapsulation layer includes at least one organic layer and at least one inorganic layer; A polarizing layer is located on the thin film encapsulation layer; A protective film is located on the second surface of the flexible substrate, with the first surface of the flexible substrate and the second surface of the flexible substrate facing away from each other; as well as An adhesive layer is located between the flexible substrate and the protective film. The width of the flexible substrate is greater than the width of the protective film, the width of the first surface of the protective film is greater than the width of the second surface of the protective film, the first surface of the protective film is close to the adhesive layer, and the second surface of the protective film is opposite to the first surface of the protective film.

10. The display device according to claim 9, wherein, The first surface of the polarization layer near the light-emitting diode and the second surface of the polarization layer have the same width, and the second surface of the polarization layer is opposite to the first surface of the polarization layer.

11. The display device according to claim 10, wherein, The polarization layer includes a polarizing film.

12. The display device according to claim 9, wherein, The width of the first surface of the adhesive layer is smaller than the width of the second surface of the adhesive layer, the first surface of the adhesive layer is close to the first surface of the protective film, and the second surface of the adhesive layer is close to the flexible substrate.

13. The display device according to claim 9, wherein, The light-emitting diode includes an organic light-emitting diode.

14. The display device according to claim 9, wherein, The thin film encapsulation layer comprises a structure in which the organic layer and the inorganic layer are stacked alternately.

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