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 support layer, an adhesive layer, a protective film, a display panel, a polarizing layer, an optical adhesive layer and a cover plate which are sequentially stacked. The support layer is a composite material layer formed by hot pressing of a metal layer and a carbon fiber layer. By setting the support layer as the composite material layer of the metal layer and the carbon fiber layer, the surface flatness of the flexible module can be improved. At the same time, the front impact resistance of the module can be improved due to the addition of the rigid material such as the metal layer. The thickness of one adhesive layer can be removed to achieve the purpose of module thinning. Moreover, the composite adhesion between the metal layer and the carbon fiber layer is better than the effect of assembling by single body bonding of the metal layer and the carbon fiber plate, so that the risk of module peeling can be reduced. The display device and the manufacturing method thereof provided by the application have the advantages of simple structure, convenient manufacturing, strong stability, low cost, effective reduction of product weight and improved display effect.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of display, in particular to a display device and a manufacturing method thereof. BACKGROUND

[0002] With the advent of smart phones, tablet computers and many other electronic products, people's requirements for the experience and comfort of electronic products are also increasingly high. In order to achieve the purpose of reducing the weight of the module, the proportion of metal materials in the product is usually reduced. The material of the support part at the back of the original module is usually metal material. At present, in order to reduce the weight, most modules use carbon fiber material to replace metal material as supporting material. However, the surface flatness of the module using carbon fiber plate is relatively poor compared with metal material, which will cause poor light and shadow on the surface of the display device, affect the optical effect of the whole machine and the arching of the bending area. Therefore, there is an urgent need for a display device that is light and has good display effect. Figure 2 SUMMARY

[0003] Therefore, the purpose of the present application is to provide a display device and a manufacturing method thereof.

[0004] In a first aspect, the present application provides a display device, comprising a support layer, an adhesive layer, a protective film, a display panel, a polarizing layer, an optical adhesive layer and a cover plate which are sequentially stacked, wherein the support layer is a composite material layer formed by hot pressing a metal layer and a carbon fiber layer.

[0005] In some embodiments, the support layer comprises one metal layer and multiple carbon fiber layers, the number of the carbon fiber layers is odd, and the axial angle of carbon filaments of adjacent two carbon fiber layers is 90°.

[0006] In some embodiments, the metal layer is located on one side of the multiple carbon fiber layers or between adjacent two carbon fiber layers.

[0007] In some embodiments, the metal layer is provided with multiple through holes arranged at intervals, or the metal layer is subjected to a roughening process.

[0008] In some embodiments, the thickness of the metal layer is 0.02mm to 0.05mm, the thickness of the carbon fiber layer located in the middle of the support layer is 0.1mm to 0.13mm, and the thickness of the remaining carbon fiber layers is 0.02mm to 0.05mm.

[0009] In some embodiments, the support layer comprises a bending area, and the bending area is formed with a first pattern.

[0010] ​In some embodiments, the metal layer is provided with a through groove along the length direction of the bending area, and the through groove is spaced apart from the bending area.

[0011] In some embodiments, the two sides of the bending area along the width direction are respectively provided with one through groove, the width of the through groove is greater than or equal to 0.1 mm, and the spacing between the through groove and the bending area is greater than or equal to 1.5 mm.

[0012] In some embodiments, the carbon fiber layer farthest from the adhesive layer is provided with a groove, the groove covers the bending area, and the groove is provided with a conductive block.

[0013] In some embodiments, the edge of the groove is spaced apart from the edge of the bending area by a distance greater than or equal to 1.5 mm.

[0014] In a second aspect of the present application, a manufacturing method of a display device is provided, which comprises layering an adhesive layer, a protective film, a display panel, a polarizing layer, an optical adhesive layer and a cover plate on a support layer, wherein the manufacturing method of the support layer comprises: layering a first glass plate, a metal layer, a carbon fiber layer, a release paper and a second glass plate, and then performing vacuumizing process, hot pressing process and patterning process to form the support layer.

[0015] In some embodiments, the temperature of the hot pressing process is 80-140°C, and the hot pressing time is less than or equal to 60 min.

[0016] As can be seen from the above, the present application provides a display device and a manufacturing method thereof, the display device comprising a support layer, an adhesive layer, a protective film, a display panel, a polarizing layer, an optical adhesive layer and a cover plate which are sequentially layered, and the support layer is a composite material layer formed by hot pressing a metal layer and a carbon fiber layer; by setting the support layer as a composite material layer of the metal layer and the carbon fiber layer, compared with the display device using pure carbon fiber plate as the support layer, the surface flatness of the flexible module can be improved, and at the same time, the front impact resistance of the module can be improved due to the addition of the rigid material such as the metal layer; compared with the display device in which the metal layer and the carbon fiber plate are directly attached to form the support layer, the thickness of one adhesive layer can be removed to achieve the purpose of module thinning, and the composite adhesion between the metal layer and the carbon fiber layer is better than the effect of assembling by single body attachment of the metal layer and the carbon fiber plate, which can reduce the risk of module peeling, and at the same time, the yield of the support layer can be improved by eliminating the etching and assembly process of the ultra-thin metal, thereby achieving the purpose of cost reduction; the display device and the manufacturing method thereof have simple structure, convenient manufacturing, strong stability and low cost, can effectively reduce the weight of the product, and improve the display effect. BRIEF DESCRIPTION OF DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the application or the related art, the drawings needed to be used in the embodiments or the related art description will be briefly introduced. Obviously, the drawings in the following description only illustrate the embodiments of the application, and other drawings can be obtained by those skilled in the art without any creative effort on the basis of these drawings.

[0018] Figure 1 It is a structural schematic diagram of a display device in the related art.

[0019] Figure 2 It is a display effect schematic diagram of the display device in the related art. Figure 1

[0020] Figure 3 It is a structural schematic diagram of another display device in the related art.

[0021] Figure 4 It is a structural schematic diagram of a display device in the embodiments of the application.

[0022] Figure 5 It is a sectional structural schematic diagram of a first support layer.

[0023] Figure 6 It is a prepreg structural schematic diagram of a carbon fiber layer.

[0024] Figure 7 It is a manufacturing process schematic diagram of the support layer in the related art. Figure 5

[0025] It is a laser cutting schematic diagram of the support layer in the related art. Figure 8 Figure 5 It is a bending area structural schematic diagram of the support layer in the related art.

[0026] Figure 9 Figure 5 It is a sectional structural schematic diagram of a second support layer.

[0027] Figure 10 It is a sectional structural schematic diagram of a third support layer.

[0028] Figure 11 It is a sectional structural schematic diagram of a fourth support layer.

[0029] Figure 12 It is a top view structural schematic diagram of the support layer in the related art.

[0030] Figure 13 It is a manufacturing process schematic diagram of the support layer in the related art. Figure 12

[0031] It is a manufacturing process schematic diagram of the support layer in the related art. Figure 14 Figure 12

[0032] ​​​​​Figure 15 A schematic view of a cross-section structure of a fifth support layer;

[0033] Figure 16 A schematic view of a top structure of a support layer; Figure 15 A schematic view of a top structure of a support layer;

[0034] Figure 17 A schematic view of a top structure of a support layer; Figure 15 A schematic view of a manufacturing process of a support layer.

[0035] FIG. 1 is a schematic view of a support layer; FIG. 1-1 is a metal layer; FIG. 1-1-1 is a through groove; FIG. 1-2 is a carbon fiber layer; FIG. 1-2-1 is a carbon wire; FIG. 1-2-2 is a resin; FIG. 1-2-3 is a groove; FIG. 1-2-4 is a conductive block; FIG. 1-3 is a first glass plate; FIG. 1-4 is a release paper; FIG. 1-5 is a second glass plate; FIG. 1-6 is a protective layer; FIG. 2 is an adhesive layer; FIG. 3 is a protective film; FIG. 4 is a display panel; FIG. 5 is a polarizing layer; FIG. 6 is an optical adhesive layer; FIG. 7 is a cover plate; FIG. 8 is a bending area; and FIG. 9 is a sealing bag. DETAILED DESCRIPTION

[0036] In order to make the objectives, technical solutions and advantages of the present application clearer, the present application will be further described in detail below with reference to specific embodiments and the accompanying drawings.

[0037] It should be noted that, unless otherwise defined, the technical terms or scientific terms used in the embodiments of the present application should be understood as their common meanings to those having ordinary skills in the art to which the present application belongs. The terms "first", "second" and similar terms used in the embodiments of the present application do not represent any order, number or importance, but are only used to distinguish different components. The terms "comprise", "include" and similar terms mean that the components or objects before the terms encompass the components or objects listed after the terms and their equivalents, and do not exclude other components or objects. The terms "connect" or "connected" and similar terms do not mean physical or mechanical connection, but can include electrical connection, whether direct or indirect. The terms "upper", "lower", "left", "right" and the like only represent relative positional relationships, which can change accordingly when the absolute positions of the described objects change.

[0038] With the advent of many electronic products such as smart phones, tablets and the like, people's requirements for the experience and comfort of electronic products are also increasingly high. In order to achieve the purpose of reducing the weight of the module, the proportion of metal materials in the product is usually reduced. The support material of the original module back is usually made of metal material. At present, in order to reduce the weight, most modules use carbon fiber material instead of metal material as the support material. However, the surface flatness of the module using carbon fiber plate is relatively poor compared with metal material, such as Figure 2As shown, it will cause the display device surface light and shadow poor, affect the whole machine optical effect and bending area arch, therefore, need a kind of lightweight and display effect good display device.

[0039] In the process of realizing the present application, it is found that the stacking structure of the existing display device is as shown in the figure Figure 1 As shown, from top to bottom are: cover plate 7, for protecting the display device, improve the anti-impact effect; optical adhesive layer 6, for bonding cover plate 7 and polarizing layer 5, while in the folding display device, low modulus optical adhesive layer 6 can reduce the stress between the layers, prevent peeling phenomenon in the process of bending module; polarizing layer 5, prevent the outside environment light on the display effect form interference, polarizing layer 5 contains glue, used to bond with display panel 4, also can be integrated into display panel 4; display panel 4, is the neutral layer of display device, can integrate touch layer (FMLOC) and polarizing layer 5 (COE); protective film 3, display panel 4 of non display surface protection structure, for balancing stress protection display panel 4, protective film 3 contains glue, used to display panel 4 with; carbon fiber layer 1-2, for providing support for flexible module, with adhesive layer 2 and display panel 4 with, in the bending area 8 of carbon fiber layer 1-2, patterned design, ensure that the module can be bent in the bending area 8, no patterned design in the non bending area 8, ensure the flatness of the module non bending area 8, but relative to the same thickness of stainless steel plate, the tensile modulus of carbon fiber layer 1-2 is slightly lower, as shown in the figure Figure 2 As shown, it will cause the module under the light reflection of light distortion phenomenon, that is, light and shadow poor. At the same time, the bending area 8 of carbon fiber layer 1-2 will have arch or indentation after a certain number of bending, affecting the appearance effect of the product.

[0040] In order to improve the light and shadow poor and module flatness problem, in some display devices, a layer of ultra-thin metal layer 1-1 will be added between carbon fiber layer 1-2 and display panel 4, the tensile modulus of metal layer 1-1 is greater than or equal to 95Gpa, the metal material can be stainless steel (SUS) and the like, the thickness of metal layer 1-1 is in the range of 0.02mm to 0.05mm, as shown in the figure Figure 3 As shown, the display panel 4 is provided with two adhesive layers 2, a metal layer 1-1 and a carbon fiber layer 1-2, the thickness of the adhesive layer 2 is in the range of 0.02mm to 0.05mm, the carbon fiber layer 1-2 usually adopts three layer prepreg stacking structure, the total thickness is in the range of 0.15mm to 0.2mm, the design scheme of increasing the support structure of metal layer 1-1 will cause the total thickness of display device to increase at least 0.05mm, at the same time, since the metal layer 1-1 is assembled with carbon fiber layer 1-2 by bonding process, the metal layer 1-1 needs to be etched into shape before bonding, the etching yield of ultra-thin metal is less than or equal to 5%, the yield of assembled support structure is generally less than or equal to 2%, resulting in the increase of the cost of support structure.

[0041] The technical solutions of the present application will be described in detail below through specific embodiments and in conjunction with Figures 4 to 17 .

[0042] In some embodiments of the present application, a display device is provided, as shown in Figure 4 , comprising a support layer 1, an adhesive layer 2, a protective film 3, a display panel 4, a polarizing layer 5, an optical adhesive layer 6 and a cover plate 7 which are sequentially stacked, the support layer 1 is a composite material layer formed by hot pressing of a metal layer 1-1 and a carbon fiber layer 1-2.

[0043] As shown in Figure 4 , the display device comprises a support layer 1, an adhesive layer 2, a protective film 3, a display panel 4, a polarizing layer 5, an optical adhesive layer 6 and a cover plate 7; the cover plate 7 is used to protect the display device and improve the resistance to external impact; the optical adhesive layer 6 is used to bond the cover plate 7 and the polarizing layer 5, and at the same time in the folded display device, the low modulus optical adhesive layer 6 can reduce the stress between the layers to prevent peeling during the bending process of the module; the polarizing layer 5 prevents external ambient light from interfering with the display effect, and the polarizing layer 5 contains glue to bond with the display panel 4; the display panel 4 is the neutral layer of the display device, which can integrate the touch layer and the polarizing layer; the protective film 3 is the non-display surface protection structure of the display panel 4, which is used to balance the stress and protect the display panel 4, and the protective film 3 contains glue for lamination with the display panel 4; the support layer 1 provides support for the flexible module, which can be patterned in the bending area 8 to ensure that the module can be bent in the bending area 8, and there is no patterned design in the non-bending area 8 to ensure the flatness of the non-bending area 8 of the module.

[0044] As shown in Figure 5 , the support layer 1 is a composite material layer formed by hot pressing of a metal layer 1-1 and a carbon fiber layer 1-2, and the manufacturing method is as shown in Figure 7 , the first glass plate 1-3, the metal layer 1-1, the carbon fiber layer 1-2, the release paper 1-4 and the second glass plate 1-5 are stacked, and then vacuumizing process, hot pressing process and patterning process are carried out to form the support layer 1; by setting the support layer 1 as a composite material layer of the metal layer 1-1 and the carbon fiber layer 1-2, compared with the display device using pure carbon fiber plate as the support layer 1, the surface flatness of the flexible module can be improved, and at the same time, since the rigid material such as the metal layer 1-1 is added, the front impact resistance of the module can be improved; compared with the display device in which the metal layer 1-1 and the carbon fiber plate are directly bonded to form the support layer 1, the thickness of one layer of adhesive layer 2 can be removed to achieve the purpose of thinning the module, and the composite adhesion between the metal layer 1-1 and the carbon fiber layer 1-2 will be better than the effect of assembling by single bonding of the metal layer 1-1 and the carbon fiber plate, which can reduce the risk of module peeling, and at the same time, since the etching and assembly process of the ultra-thin metal is omitted, the yield of the support layer 1 can be improved to achieve the purpose of cost reduction.

[0045] The display device has simple structure, easy manufacturing, high stability and low cost, can effectively reduce the weight of the product, and improve the display effect.

[0046] In some embodiments, as shown in Figure 5 , the support layer 1 includes a metal layer 1-1 and a plurality of carbon fiber layers 1-2, the number of carbon fiber layers 1-2 is odd, and the axial angle of carbon filaments of adjacent two carbon fiber layers 1-2 is 90°.

[0047] As shown in Figure 5 , the support layer 1 includes a metal layer 1-1 and a plurality of carbon fiber layers 1-2, the number of carbon fiber layers 1-2 is odd, for example, 3 layers, 5 layers, etc., as shown in Figure 7 , the axial angle of carbon filaments of adjacent two carbon fiber layers 1-2 is 90°, that is, the carbon fiber layers 1-2 are orthogonally arranged, which ensures that the carbon fiber layers 1-2 as a whole can achieve high modulus and improve flatness.

[0048] In some embodiments, as shown in Figure 5 , Figure 10 and Figure 11 , the metal layer 1-1 is located on one side of the plurality of carbon fiber layers 1-2, or between adjacent two carbon fiber layers 1-2.

[0049] As shown in Figure 5 , the metal layer 1-1 can be arranged on one side of the plurality of carbon fiber layers 1-2, which can improve the rigidity and flatness of the display device, as shown in Figure 10 and Figure 11 , the metal layer 1-1 can also be arranged between adjacent two carbon fiber layers 1-2, which can improve the rigidity of the carbon fiber layers 1-2 as a whole.

[0050] As shown in Figure 5 , the ultra-thin metal layer 1-1 is arranged on one side of the adhesive layer 2, and is arranged close to the display panel 4 in the stack of the flexible display device. The ultra-thin metal can be designed with full holes or roughened, which is beneficial to the combination of the metal with the resin 1-2-2 and the fiber. The adhesive layer 2 is double-sided adhesive or photocuring (OCA) adhesive; the metal layer 1-1 is ultra-thin metal, and the material is SUS or titanium alloy; the carbon fiber layer 1-2 is three layers of prepreg. The ultra-thin metal and carbon fiber composite process flow is referred to Figure 7 , and the support layer 1 and the adhesive layer 2 are realized by sheet lamination process.

[0051] As shown in Figure 10The support layer 1 is shown, and the ultra-thin metal layer 1-1 is arranged between the three carbon fiber layers 1-2. The ultra-thin metal can be selected to have a full-surface opening design or roughening treatment, which facilitates better bonding of the metal with the resin 1-2-2 and the fibers. The adhesive layer 2 is double-sided adhesive or photocurable adhesive, the metal layer 1-1 is ultra-thin metal, the material is SUS or titanium alloy, and the carbon fiber layer 1-2 is three layers of prepreg. The ultra-thin metal and carbon fiber composite process flow is as follows: Figure 7 Only the stacking order of the metal layer 1-1 and the carbon fiber layer 1-2 is changed, and the support layer 1 and the adhesive layer 2 are bonded by a sheet bonding process.

[0052] In some embodiments, the metal layer 1-1 is provided with a plurality of spaced vias, or the metal layer 1-1 is treated by a roughening process.

[0053] The metal layer 1-1 can be provided with vias or roughened on the surface before being combined with the carbon fiber layer 1-2, which facilitates better bonding of the metal with the resin 1-2-2 and the fibers.

[0054] In some embodiments, the thickness of the metal layer 1-1 is 0.02mm to 0.05mm, and the thickness of the carbon fiber layer 1-2 located in the middle of the support layer 1 is 0.1mm to 0.13mm, and the thickness of the remaining carbon fiber layer 1-2 is 0.02mm to 0.05mm.

[0055] The thickness of the metal layer 1-1 is 0.02mm to 0.05mm, for example, 0.02mm, 0.03mm, 0.04mm or 0.05mm; when the carbon fiber layer 1-2 is three layers, the thickness of the middle carbon fiber layer 1-2 is 0.1mm to 0.13mm, for example, 0.1mm, 0.11mm, 0.121mm or 0.13mm, and the thickness of the top and bottom carbon fiber layers 1-2 is 0.02mm to 0.05mm, for example, 0.02mm, 0.03mm, 0.04mm or 0.05mm, to achieve the form of thick middle carbon fiber layer 1-2 and thin end carbon fiber layer 1-2, to ensure that the overall carbon fiber layer 1-2 reaches a higher modulus.

[0056] In some embodiments, as shown in Figure 9 The support layer 1 includes a bending area 8, and the bending area 8 is formed with a first pattern.

[0057] As shown in Figure 9 The first pattern is formed by laser cutting in the bending area 8, and the first pattern is, for example, a through hole arranged in a staggered manner, so that the bending area 8 is easy to fold.

[0058] In some embodiments, as shown in Figure 12 and Figure 13As shown in the figure, the L direction is the length direction of the bending area 8, the W direction is the width direction of the bending area 8, the metal layer 1-1 is provided with a through slot 1-1-1 along the length direction of the bending area 8, and the through slot 1-1-1 is arranged in a spaced manner with the bending area 8.

[0059] As shown in the figure, Figure 12 and Figure 13 the metal layer 1-1 is provided with a through slot 1-1-1 outside the bending area 8, which can provide a capacity space for folding operation and avoid the bending area 8 from arching or denting.

[0060] As shown in the figure, Figure 12 the adhesive layer 2 is double-sided adhesive or photocuring adhesive, the metal layer 1-1 is ultra-thin metal, and the material is SUS or titanium alloy; the carbon fiber layer 1-2 is three-layer prepreg. The ultra-thin metal and carbon fiber composite process flow refers to Figure 14 , including arranging protective layers 1-6 on both sides of the metal layer 1-1, forming a through slot 1-1-1 by laser cutting one side of the protective layer 1-6 and the metal layer 1-1, and not cutting the other protective layer 1-6. After removing the cut protective layer 1-6, pre-pressing the metal layer 1-1 and the prepreg of the carbon fiber layer 1-2, removing the other protective layer 1-6, and then stacking the glass plate and the release paper 1-4 to perform vacuumizing and hot pressing process.

[0061] In some embodiments, as shown in the figure, Figure 13 the bending area 8 is provided with one through slot 1-1-1 on each side along the width direction, the width of the through slot 1-1-1 is greater than or equal to 0.1 mm, and the spacing between the through slot 1-1-1 and the bending area 8 is greater than or equal to 1.5 mm.

[0062] As shown in the figure, Figure 13 both sides of the bending area 8 are provided with a through slot 1-1-1, which further provides folding capacity and avoids the bending area 8 from arching or denting, and the metal layer 1-1 is designed to be intermittent. In the figure, a is the width of the through slot 1-1-1, which is greater than or equal to 0.1 mm and can be adjusted according to folding requirements. The spacing between the through slot 1-1-1 and the bending area 8 is greater than or equal to 1.5 mm. When making a sample, the ultra-thin metal is first made intermittently, which can be processed by laser or etching. After the through slot 1-1-1 is opened, attention should be paid to maintaining the spacing with the bending area 8 to prevent metal lamination. In addition, the through slot 1-1-1 can be prevented from deforming by additional film covering.

[0063] In some embodiments, as shown in the figure, Figure 15 and Figure 16 the carbon fiber layer 1-2 farthest from the adhesive layer 2 is provided with a groove 1-2-3, the groove 1-2-3 covers the bending area 8, and the groove 1-2-3 is provided with a conductive block 1-2-4.

[0064] As Figure 15 shown, the carbon fiber layer 1-2 of the non-adhesive surface of the support layer 1 is provided with a groove 1-2-3, which is a through hole arranged along the length direction of the bending area 8 and covers the bending area 8. The groove 1-2-3 is filled with a conductive block 1-2-4, which is made of the same material as the metal layer 1-1, for example, for module electrical conduction.

[0065] The manufacturing process is as Figure 17 shown, etching a groove 1-2-3 on the three-layer carbon fiber layer 1-2, then depositing a conductive block 1-2-4, and then laminating a glass plate and a release paper 1-4, and performing vacuum and hot pressing process.

[0066] In some embodiments, as Figure 16 shown, the edge of the groove 1-2-3 is spaced apart from the edge of the bending area 8 by a distance greater than or equal to 1.5 mm.

[0067] As Figure 16 shown, b is the distance between the edge of the groove 1-2-3 and the edge of the bending area 8, and b is greater than or equal to 1.5 mm, which ensures that the conductive block 1-2-4 can cover the bending area 8.

[0068] In some embodiments, the display panel 4 comprises: a thin film packaging layer arranged on the outermost layer of the display panel 4, for blocking dust and water vapor from the outside, preventing the dust and water vapor from the outside from affecting the internal film layer; a thin film transistor array layer arranged on one side of the thin film packaging layer; an OLED device layer arranged on the side of the thin film transistor array layer away from the thin film packaging layer, comprising a plurality of OLED display devices, the OLED display device comprising an anode layer, a cathode layer, a light-emitting functional layer, an electron transport layer, a hole transport layer, and a hole injection layer, wherein the anode layer is electrically connected to the drain of the thin film transistor array layer; the material of the cathode layer adopts a low work function material, which can improve the efficiency of electron injection and reduce the Joule heat generated during OLED operation, thereby improving the service life of the device.

[0069] The light-emitting functional layer is used for light emission, and multiple light-emitting layers are arranged to improve the light-emitting brightness of the OLED device. The light-emitting layer can include a host material and a dopant material doped in the host material, and the doping ratio of the dopant material in the light-emitting layer is 1% to 20%. Within the range of the doping ratio, on the one hand, the host material in the light-emitting layer can effectively transfer the exciton energy to the dopant material in the light-emitting layer to excite the dopant material in the light-emitting layer to emit light, and on the other hand, the host material in the light-emitting layer can dilute the dopant material in the light-emitting layer, effectively improve the fluorescence quenching caused by the mutual collision between molecules and the mutual collision between energies of the dopant material in the light-emitting layer, and improve the light-emitting efficiency and the device life. In an example embodiment, the doping ratio refers to the ratio of the mass of the dopant material to the mass of the light-emitting layer, that is, the mass percentage. In an example embodiment, the host material and the dopant material can be co-evaporated by a multi-source evaporation process to uniformly disperse the host material and the dopant material in the light-emitting layer 3-1. The doping ratio can be adjusted by controlling the evaporation rate of the dopant material during the evaporation process, or by controlling the evaporation rate ratio of the host material and the dopant material.

[0070] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to limit the scope of the application (including claims) to these examples; 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 changes of different aspects of the embodiments of the application as described above, which are not provided in detail for the sake of brevity.

[0071] In the embodiments of the present application, "film" and "layer" can be exchanged with each other. For example, "conductive layer" can be replaced by "conductive film" sometimes. Similarly, "insulating film" can be replaced by "insulating layer" sometimes. The scale of the drawings in the embodiments of the present application can be used as a reference in the actual process, but is not limited thereto. For example, the width-length ratio of the channel, the thickness and spacing of each film layer can be adjusted according to actual needs. The number of pixels in the array substrate and the number of sub-pixels in each pixel are not limited to the number shown in the drawings. The drawings described in the embodiments of the present application are only schematic diagrams, and one way in the embodiments of the present application is not limited to the shapes or values shown in the drawings.

[0072] In the embodiments of the present application, a triangle, a rectangle, a trapezoid, a pentagon, or a hexagon is not strictly in the sense that it can be an approximate triangle, rectangle, trapezoid, pentagon, or hexagon, and there can be some small deformations caused by tolerances, and there can be lead angles, arc edges, and deformations.

[0073] Furthermore, given that details have been set forth to describe exemplary embodiments of this application, it will be apparent to those skilled in the art that embodiments of this application may be practiced without these details or with variations thereof. Therefore, these descriptions should be considered illustrative rather than restrictive.

[0074] In some embodiments of this application, a method for manufacturing a display device is provided, comprising stacking an adhesive layer 2, a protective film 3, a display panel 4, a polarizing layer 5, an optical adhesive layer 6, and a cover plate 7 on a support layer 1. The method for preparing the support layer 1 includes: stacking a first glass plate 1-3, a metal layer 1-1, a carbon fiber layer 1-2, a release paper 1-4, and a second glass plate 1-5, and then performing a vacuuming process, a hot pressing process, and a patterning process to form the support layer 1.

[0075] By extruding a metal layer 1-1 and a carbon fiber layer 1-2 through a double-layer glass plate, and forming a support layer 1 through vacuuming and hot pressing, the intermediate adhesive layer is eliminated, which can achieve module thinning while improving module flatness.

[0076] like Figure 6 As shown, this is the production of the lower-level prepreg of carbon fiber layer 1-2. The prepreg is composed of resin 1-2-2 and carbon filament 1-2-1. In folded products, the commonly used resin 1-2-2 is bisphenol A type resin. After the resin 1-2-2 with added curing agent is heated to form a film, it is then compounded with carbon filament 1-2-1 to form the prepreg. The three layers of prepreg are stacked in a 90°-0°-90° manner. The thickness of the prepreg in the 90° direction is generally 0.02mm to 0.05mm, and the thickness of the prepreg in the 0° direction is generally 0.1mm to 0.13mm. The carbon filament 1-2-1 used in the prepreg can be of models such as T700 and M40.

[0077] like Figure 7 As shown, a metal layer 1-1 is added to one side of the three-layer carbon fiber layer 1-2 to facilitate subsequent hot pressing to form a metal-carbon fiber composite material. To ensure better bonding between the metal, carbon fiber, and resin, the surface of the metal layer 1-1 can be roughened to increase the contact area, or through-holes can be added to the metal layer 1-1 to improve the bonding force between the resin 1-2-2 and the metal layer 1-1. After the prepreg and metal layer 1-1 are laid, a first glass plate 1-3 coated with release agent is placed on one side to ensure the flatness of the plate, and release paper 1-4 is placed on the other side. A second glass plate 1-5 is then added to the outside of the release paper 1-4. That is, the metal and prepreg need to be fixed and pressed together by double-layer glass plates. After completing the above steps, it is placed in a sealed bag 9 and vacuumed. The sealed bag 9 is then placed in a hot autoclave for high-temperature hot pressing. The hot pressing temperature is generally between 80℃ and 140℃, and the hot pressing time is generally ≤60min.

[0078] likeFigure 8 As shown, after hot pressing, the folding product is processed according to the design requirements of the graphic process, and a laser processing method can be used. According to the thickness of the different support layers 1, the appropriate laser process parameters are verified and adjusted for laser cutting. The laser starts cutting from the side of the release paper 1-4, and an additional protective layer 1-6 needs to be attached to the metal layer 1-1 side to prevent the formation of reverse burning accumulation in the metal layer 1-1 during laser cutting. The cutting waste generated on the metal layer 1-1 side can be removed by tearing off the protective film 3. After cutting, the metal layer 1-1 side is surface treated and then attached to the adhesive layer 2.

[0079] The "graphic process" described in the embodiments of the present application includes coating photoresist, mask exposure, development, etching, and stripping photoresist for metal materials, inorganic materials, or transparent conductive materials, and includes coating organic materials, mask exposure, and development for organic materials. Deposition can use any one or more of sputtering, evaporation, and chemical vapor deposition, coating can use any one or more of spraying, spin coating, and inkjet printing, and etching can use any one or more of dry etching and wet etching, without limitation.

[0080] It should be understood by those of ordinary skill in the art that the above discussion of any of the embodiments is merely exemplary and is not intended to suggest the scope of the present application (including claims) is limited to these examples; under the concept of the present application, the above embodiments or technical features between different embodiments can also be combined, the steps can be implemented in any order, and there are many other changes of different aspects of the embodiments of the present application as described above. In order to be brief, they are not provided in detail.

[0081] In addition, in order to simplify the description and discussion, and so as not to make the embodiments of the present application difficult to understand, the known power / ground connections with other components can or can not be shown in the provided drawings. In addition, the devices can be shown in the form of block diagrams in order to avoid making the embodiments of the present application difficult to understand, and this also takes into account the fact that the details of the implementation of these block diagram devices are highly dependent on the platform on which the embodiments of the present application are to be implemented (i.e. these details should be entirely within the understanding of those skilled in the art). With the specific details set forth to describe the exemplary embodiments of the present application, it is obvious to those skilled in the art that the embodiments of the present application can be implemented without these specific details or with variations of these specific details. Therefore, these descriptions should be considered as illustrative rather than limiting.

[0082] While the present application has been described in connection with specific embodiments thereof, it will be understood that many modifications, substitutions, and changes will be apparent to those of ordinary skill in the art. It is intended that the application embodiments encompass all such substitutions, modifications, and changes as fall within the scope of the appended claims. Accordingly, any one or more features of any embodiment are not mandatory in all embodiments. Therefore, the scope of the application should be determined by the appended claims and their legal equivalents rather than by the description of the application embodiments.

Claims

1. A display device, characterized in that, The device comprises a support layer, an adhesive layer, a protective film, a display panel, a polarizing layer, an optical adhesive layer, and a cover plate, which are stacked sequentially. The support layer is a composite material layer formed by hot pressing a metal layer and a carbon fiber layer. The support layer includes one metal layer and multiple carbon fiber layers, with an odd number of carbon fiber layers and an axial angle of 90° between the carbon filaments of adjacent carbon fiber layers. The thickness of the metal layer is 0.02 mm to 0.05 mm, the thickness of the carbon fiber layer located in the middle of the support layer is 0.1 mm to 0.13 mm, and the thickness of the remaining carbon fiber layers is 0.02 mm to 0.05 mm.

2. The display device according to claim 1, characterized in that, The metal layer is located on one side of the multiple carbon fiber layers, or between two adjacent carbon fiber layers.

3. The display device according to claim 1, characterized in that, The metal layer has multiple spaced-apart vias, or the metal layer has undergone a roughening process.

4. The display device according to claim 1, characterized in that, The support layer includes a bending region, which is formed with a first pattern.

5. The display device according to claim 4, characterized in that, The metal layer has through grooves along the length of the bending area, and the through grooves are spaced apart from the bending area.

6. The display device according to claim 5, characterized in that, The bending area has a through groove on each side along the width direction, the width of the through groove is greater than or equal to 0.1 mm, and the distance between the through groove and the bending area is greater than or equal to 1.5 mm.

7. The display device according to claim 4, characterized in that, A groove is provided on the carbon fiber layer furthest from the adhesive layer, the groove covers the bending area, and a conductive block is provided in the groove.

8. The display device according to claim 7, characterized in that, The distance between the edge of the groove and the edge of the bending area is greater than or equal to 1.5 mm.

9. A method for manufacturing a display device according to any one of claims 1-8, characterized in that, The method includes stacking an adhesive layer, a protective film, a display panel, a polarizing layer, an optical adhesive layer, and a cover plate on a support layer. The support layer is prepared by stacking a first glass plate, a metal layer, a carbon fiber layer, a release paper, and a second glass plate, and then performing a vacuuming process, a hot pressing process, and a patterning process to form the support layer.

10. The method for manufacturing a display device according to claim 9, characterized in that, The hot pressing process is carried out at a temperature of 80°C to 140°C, and the hot pressing time is less than or equal to 60 minutes.

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