A method for laminating and manufacturing a hyperbolic glass display screen

Abstract

The present invention discloses a method for laminating a hyperbolic glass display screen, comprising the following steps: preparing a first laminate; preparing a deformation tool: preparing two sets of the first deformation tool and the second deformation tool according to the curvature of a second curved glass substrate; preparing a second laminate: obtaining the second laminate using the deformation tool; preparing a third laminate: laminating and laminating the first laminate, the second laminate, a Teflon film, a buffer layer, a Teflon film, and a second curved glass pressing plate in this order to form a third laminate; wrapping the third laminate with two sets of upper and lower polyurethane films, evacuating the interior of the laminate, placing the laminate in an autoclave under high temperature and pressure, and removing the polyurethane film, the second curved glass pressing plate, the Teflon film, the buffer adhesive layer, and the Teflon film after exiting the autoclave, thereby finally forming a hyperbolic glass display screen. The present invention has the advantage of reducing the defective rate of display screen breakage during production and improving the yield rate.

Description

Technical Field

[0001] The present invention relates to the technical field of display screen manufacturing, and in particular to a method for laminating and manufacturing a hyperbolic glass display screen. Background Art

[0002] Laminated flat glass with display functions is increasingly being used in various applications, and the manufacturing process for flat-panel display glass is quite mature. Single-curved displays are also seeing limited adoption, but hyperbolic displays have yet to enter the market. This difficulty stems from the fact that during the production process, the laminating substrate (typically glass) is hyperbolic, while the display is flat. The two are bonded together through a special high-temperature pre-pressing or vacuuming process, as well as high-temperature and high-pressure processes, to permanently bond the hyperbolic glass and OLED display into a single composite glass product. However, during production, stress and springback often cause the adhesive layer of the OLED display to separate, the FPC cables to break, and the display to tear. This results in low product yields and increased production costs.

[0003] At present, the preparation method of hyperbolic OLED display laminated glass is mainly based on the flat-panel lamination process to composite OLED display screen. The production process is as follows:

[0004] ① Lamination: Place the intermediate buffer organic adhesive layer between two pieces of hyperbolic glass, and trim off the excess organic adhesive layer at the edges; then place another organic adhesive layer on the upper glass surface, and place the OLED display on top of the adhesive layer, trimming off the excess organic adhesive layer at the edges of the display.

[0005] ② Vacuuming: Place the entire laminate into a sealed bag made of polyurethane film, remove the air in the sealed bag through a vacuum tube, and then send it into an autoclave for high-pressure treatment;

[0006] ③ High pressure: The vacuum laminate is placed in an autoclave and subjected to high temperature and high pressure for a long time to form laminated glass.

[0007] Since the OLED display is flat, it will deform after being bonded to the curved glass. When high-pressure production is performed after the lamination is completed, the surface of the OLED display will be compressed, resulting in uneven pressure due to the difference in film thickness. As a result, the display will shatter due to uneven pressure during the high-pressure process. Summary of the Invention

[0008] The purpose of the present invention is to provide a method for laminating a hyperbolic glass display screen, in which a bonding layer and an OLED display screen are separated and laminated in a step-by-step manner. The bonding layer is first fixed, and when the OLED display screen is laminated, a bonding buffer layer is added between the OLED display screen and the pressing plate to reduce the pressure, thereby reducing the defective rate of display screen breakage during production and improving the yield rate.

[0009] The above technical objectives of the present invention are achieved through the following technical solutions:

[0010] A method for laminating a hyperbolic glass display screen, characterized by comprising the following steps:

[0011] Preparation of a first laminate: laminating a first curved glass substrate, a first film adhesive layer, a second curved glass substrate, a second film adhesive layer, a Teflon film, a nylon mesh, and a first curved glass pressing plate in this order, then wrapping the laminate with two sets of upper and lower polyurethane films, evacuating the interior, placing the laminate in an autoclave under high temperature and pressure, and removing the polyurethane films, glass pressing plate, nylon mesh, and Teflon film in this order to obtain the first laminate;

[0012] Preparing a deformation tool: preparing two sets of a first deformation tool and a second deformation tool according to the curvature of the second curved glass substrate;

[0013] Preparation of a second laminate: laminating and bonding the first deforming tool, the buffer layer, the Teflon film, the third film adhesive layer, the OLED display, the Teflon film, the buffer layer, and the first deforming tool in this order, followed by a first constant temperature deformation treatment. After removing the first deforming tool, the two sides are bonded and fixed with the second deforming tool to obtain a second laminate;

[0014] Preparation of the third laminate: The first laminate, the second laminate, the Teflon film, the buffer layer, the Teflon film, and the second curved glass platen are stacked and bonded again in this order to form a third laminate. The third laminate is wrapped with two sets of upper and lower polyurethane films, and the interior is evacuated. The laminate is placed in an autoclave and subjected to high-temperature pressure treatment. After the laminate is removed from the autoclave, the polyurethane film, the second curved glass platen, the Teflon film, the buffer adhesive layer, and the Teflon film are removed in turn to finally form a hyperbolic glass display.

[0015] Preferably, the thickness of the first curved glass platen and the second curved glass platen are both 4-6 mm, the four sides of the first curved glass platen protrude from the outer edge of the OLED display screen by 0-10 mm, and the four sides of the second curved glass platen protrude from the outer edge of the OLED display screen by 0-2 mm.

[0016] Preferably, the first film adhesive layer, the second film adhesive layer and the third film adhesive layer are all selected from one of PVB, EVA, PU and TPU.

[0017] Preferably, the first curved glass pressing plate, the second curved glass pressing plate, the first curved glass substrate and the second curved glass substrate are all made of tempered glass or silicate clear glass.

[0018] Preferably, the high temperature pressurization treatment of the first stack is specifically as follows: heating to 50°C and pressurizing to 0.1Mpa at the same time, maintaining for 30 minutes, then heating to 80°C and pressurizing to 0.5Mpa, maintaining for 30 minutes, continuing to heat to 110°C, pressurizing to 1.2Mpa, maintaining for 90 minutes, then cooling to 20°C, maintaining for 50 minutes, reducing the pressure to 0Mpa and opening the autoclave, wherein the heating frequency is 1°C / minute, and the cooling frequency is 1°C / minute.

[0019] Preferably, the high temperature pressurization treatment of the third stack is specifically as follows: heating to 40°C and pressurizing to 0.1Mpa at the same time, maintaining for 30 minutes, then heating to 60°C and pressurizing to 0.5Mpa, maintaining for 30 minutes, continuing to heat to 90°C, pressurizing to 1.2Mpa, maintaining for 240 minutes, then cooling to 25°C, maintaining for 50 minutes, reducing the pressure to 0Mpa and opening the autoclave, wherein the heating frequency is 2°C / minute, and the cooling frequency is 1.2°C / minute.

[0020] Preferably, the specific operation of vacuuming the interior of the first stack and the third stack is: vacuum extraction is performed under an environment where the temperature is controlled at 15-30°C and the humidity is ≤55%, the vacuum pressure is controlled at 0.08-0.1Mpa, and the vacuum extraction time is 4-10 hours.

[0021] Preferably, the buffer layer is made of silicone material.

[0022] Preferably, the curvature of the first deformation tool is half of that of the second curved glass substrate, and the curvature of the second deformation tool is the same as that of the second curved glass substrate.

[0023] Preferably, in preparing the second laminate, the first isothermal deformation treatment temperature is 60-110° C., the isothermal time is 4-16 hours, and the second isothermal deformation treatment temperature is 80-110° C., the isothermal time is 4-16 hours.

[0024] In summary, the beneficial effects of the present invention are as follows: the adhesive layer and the OLED display are separated for lamination production by a step-by-step method, the adhesive layer is first fixed, and when the OLED display is laminated, an adhesive buffer layer is added between the OLED display and the pressing plate to reduce the pressure, thereby reducing the defective rate of display breakage during production and improving the yield rate. DETAILED DESCRIPTION

[0025] The following is a further description of the specific embodiments of the present invention, which do not limit the present invention.

[0026] A method for laminating a hyperbolic glass display screen comprises the following steps:

[0027] Preparation of a first laminate: laminating and bonding the first curved glass substrate, the first film adhesive layer, the second curved glass substrate, the second film adhesive layer, the Teflon film, the nylon mesh, and the first curved glass pressing plate in sequence, and then wrapping and covering the laminate with two sets of upper and lower polyurethane films and then evacuating the interior. The polyurethane film needs to be cut according to the size of the laminate, and the cutting size is 300-800 mm longer than the length of the laminate and 200-500 mm wider than the width of the laminate. One side of the polyurethane film is affixed with a sealing tape for complete sealing to form an enclosed space, and the laminate is placed in an autoclave for high-temperature pressure treatment. After exiting the autoclave, the polyurethane film, the glass pressing plate, the nylon mesh, and the Teflon film are removed in sequence to obtain a first laminate, wherein the Teflon film and the nylon mesh are 50 mm to 100 mm longer than the first curved glass pressing plate. After the lamination is completed, the excess portions of the Teflon film and the nylon mesh need to be turned over and covered on the upper surface of the first curved glass pressing plate and fixed.

[0028] Preparing a deformation tool: preparing two sets of a first deformation tool and a second deformation tool according to the curvature of the second curved glass substrate;

[0029] Preparation of the second laminate: stacking and laminating in the order of the first deformation tooling, buffer layer, Teflon film, third film adhesive layer, OLED display, Teflon film, buffer layer, and first deformation tooling. The buffer layer and the first deformation tooling are of the same size, and the Teflon film must exceed the first deformation tooling by 50-60mm. Subsequently, the first constant temperature deformation treatment is performed. After removing the first deformation tooling, the two sides are fixed with the second deformation tooling to obtain the second laminate. The first deformation tooling and the second deformation tooling are of the same size as the OLED displaying screen.

[0030] Prepare the third stack: stack and bond the first stack, the second stack, the Teflon film, the buffer layer, the Teflon film, and the second curved glass platen in this order to form a third stack. The size of the buffer layer is consistent with the size of the OLED display screen. The inner and outer surfaces of the buffer layer need to be wrapped with Teflon film for later removal. Wrap the third stack with two sets of upper and lower polyurethane films and then evacuate the interior. The polyurethane film needs to be cut according to the size of the stack. The cutting size is 300-800mm longer than the length of the stack and 200-500mm wider than the width of the stack. Stick a sealing tape on one side of the polyurethane film to completely seal it to form an enclosed space. Place it in an autoclave for high-temperature and pressure treatment. After leaving the autoclave, remove the polyurethane film, the second curved glass platen, the Teflon film, the buffer adhesive layer and the Teflon film in turn to finally form a hyperbolic glass display screen.

[0031] The thickness of the first curved glass platen and the second curved glass platen are both 4-6mm. The four sides of the first curved glass platen protrude 0-10mm from the outer edge of the OLED display screen, and the four sides of the second curved glass platen protrude 0-2mm from the outer edge of the OLED display screen.

[0032] The first film adhesive layer, the second film adhesive layer and the third film adhesive layer are all selected from one of PVB, EVA, PU and TPU.

[0033] The first curved glass pressing plate, the second curved glass pressing plate, the first curved glass substrate and the second curved glass substrate are all made of tempered glass or silicate clear glass.

[0034] The high-temperature pressurization treatment of the first stack is specifically as follows: heating to 50°C and pressurizing to 0.1 MPa at the same time, maintaining for 30 minutes, then heating to 80°C and pressurizing to 0.5 MPa, maintaining for 30 minutes, continuing to heat to 110°C, pressurizing to 1.2 MPa, maintaining for 90 minutes, then cooling to 20°C, maintaining for 50 minutes, reducing the pressure to 0 MPa and opening the autoclave, wherein the heating frequency is 1°C / minute, and the cooling frequency is 1°C / minute.

[0035] The high-temperature pressurization treatment of the third stack is specifically as follows: heating to 40°C and pressurizing to 0.1 MPa at the same time, maintaining for 30 minutes, then heating to 60°C and pressurizing to 0.5 MPa, maintaining for 30 minutes, continuing to heat to 90°C, pressurizing to 1.2 MPa, maintaining for 240 minutes, then cooling to 25°C, maintaining for 50 minutes, reducing the pressure to 0 MPa and opening the autoclave, wherein the heating frequency is 2°C / minute, and the cooling frequency is 1.2°C / minute.

[0036] The specific operation of vacuuming the interior of the first stack and the third stack is: vacuum extraction is performed under an environment with a temperature of 15-30°C and a humidity of ≤55%, a vacuum pressure of 0.08-0.1 MPa, and a vacuum extraction time of 4-10 hours.

[0037] The buffer layer is made of silicone.

[0038] The curvature of the first deformation tool is half of that of the second curved glass substrate, and the curvature of the second deformation tool is the same as that of the second curved glass substrate.

[0039] In preparing the second laminate, the first constant temperature deformation treatment temperature is 60-110° C., the constant temperature time is 4-16 hours, and the second constant temperature deformation treatment temperature is 80-110° C., the constant temperature time is 4-16 hours.

[0040] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art may make various modifications or equivalent substitutions to the present invention within the essence and protection scope of the present invention, and such modifications or equivalent substitutions should also be deemed to fall within the protection scope of the technical solution of the present invention.

Claims

1. A method for laminating a hyperbolic glass display screen, characterized in that: The steps include: Preparation of a first laminate: laminating a first curved glass substrate, a first film adhesive layer, a second curved glass substrate, a second film adhesive layer, a Teflon film, a nylon mesh, and a first curved glass pressing plate in this order, then wrapping the laminate with two sets of upper and lower polyurethane films, evacuating the interior, placing the laminate in an autoclave under high temperature and pressure, and removing the polyurethane films, glass pressing plate, nylon mesh, and Teflon film in this order to obtain the first laminate; Preparing a deformation tool: two sets of first deformation tools and second deformation tools are prepared according to the curvature of the second curved glass substrate, wherein the curvature of the first deformation tool is half that of the second curved glass substrate, and the curvature of the second deformation tool is the same as that of the second curved glass substrate; Preparation of a second laminate: laminating and bonding the first deforming tool, the buffer layer, the Teflon film, the third film adhesive layer, the OLED display, the Teflon film, the buffer layer, and the first deforming tool in this order, followed by a first constant temperature deformation treatment. After removing the first deforming tool, the two sides are bonded and fixed with the second deforming tool to obtain a second laminate; Preparation of the third laminate: The first laminate, the second laminate, the Teflon film, the buffer layer, the Teflon film, and the second curved glass platen are stacked and bonded again in this order to form a third laminate. The third laminate is wrapped with two sets of upper and lower polyurethane films, and the interior is evacuated. The laminate is placed in an autoclave and subjected to high-temperature pressure treatment. After the laminate is removed from the autoclave, the polyurethane film, the second curved glass platen, the Teflon film, the buffer adhesive layer, and the Teflon film are removed in turn to finally form a hyperbolic glass display.

2. The method for laminating a hyperbolic glass display screen according to claim 1, wherein: The thickness of the first curved glass platen and the second curved glass platen are both 4-6 mm. The four sides of the first curved glass platen protrude from the outer edge of the OLED display screen by 0-10 mm, and the four sides of the second curved glass platen protrude from the outer edge of the OLED display screen by 0-2 mm.

3. The method for laminating a hyperbolic glass display screen according to claim 1, wherein: The first film adhesive layer, the second film adhesive layer and the third film adhesive layer are all selected from one of PVB, EVA, PU and TPU.

4. The method for laminating a hyperbolic glass display screen according to claim 1, wherein: The first curved glass pressing plate, the second curved glass pressing plate, the first curved glass substrate and the second curved glass substrate are all made of tempered glass or silicate clear glass.

5. The method for laminating a hyperbolic glass display screen according to claim 1, wherein: The high-temperature pressurization treatment of the first stack is specifically as follows: heating to 50°C and pressurizing to 0.1 MPa at the same time, maintaining for 30 minutes, then heating to 80°C and pressurizing to 0.5 MPa, maintaining for 30 minutes, continuing to heat to 110°C, pressurizing to 1.2 MPa, maintaining for 90 minutes, then cooling to 20°C, maintaining for 50 minutes, reducing the pressure to 0 MPa and opening the autoclave, wherein the heating frequency is 1°C / minute, and the cooling frequency is 1°C / minute.

6. The method for laminating a hyperbolic glass display screen according to claim 1, wherein: The high-temperature pressurization treatment of the third stack is specifically as follows: heating to 40°C and pressurizing to 0.1 MPa at the same time, maintaining for 30 minutes, then heating to 60°C and pressurizing to 0.5 MPa, maintaining for 30 minutes, continuing to heat to 90°C, pressurizing to 1.2 MPa, maintaining for 240 minutes, then cooling to 25°C, maintaining for 50 minutes, reducing the pressure to 0 MPa and opening the autoclave, wherein the heating frequency is 2°C / minute, and the cooling frequency is 1.2°C / minute.

7. The method for laminating a hyperbolic glass display screen according to claim 1, wherein: The specific operation of vacuuming the interior of the first stack and the third stack is: vacuum extraction is performed under an environment where the temperature is controlled at 15-30°C and the humidity is ≤55%, the vacuum pressure is controlled at 0.08-0.1 MPa, and the vacuum extraction time is 4-10 hours.

8. The method for laminating a hyperbolic glass display screen according to claim 1, wherein: The buffer layer is made of silicone.

9. The method for laminating a hyperbolic glass display screen according to claim 1, wherein: The first constant temperature deformation treatment temperature in preparing the second laminate is 60-110° C., and the constant temperature time is 4-16 hours.