Apparatus for manufacturing display device

Abstract

An apparatus for manufacturing a display device includes: an application head configured to apply an adhesive material to an object; and a selective curing module configured to cure a portion of the adhesive material, where the selective curing module is configured to cure an edge portion of the adhesive material.

Description

[0001] This application claims priority to Korean Patent Application No. 10-2023-0179531, filed on December 12, 2023, and all benefits therefrom, the contents of which are incorporated herein in their entirety by reference. TECHNICAL FIELD

[0002] The present disclosure relates to an apparatus for manufacturing a display device and a method for manufacturing a display device. BACKGROUND

[0003] As the information society develops, the demand for display devices for displaying images has increased in various fields. The display device can be, for example, a liquid crystal display (LCD), a field emission display (FED), or a light emitting display (LED). The light emitting display can include an organic light emitting display including an organic light emitting diode element as a light emitting element, an inorganic light emitting display including an inorganic light emitting diode element as a light emitting element, and the like.

[0004] The display device can include a display panel including a light emitting element, and a window member can be disposed on the display panel to protect the display panel from external impact. The window member can be disposed on the display panel by an adhesive member. SUMMARY

[0005] Embodiments of the present disclosure provide an apparatus for manufacturing a display device and a method for manufacturing a display device, in which the adhesive strength and adhesive reliability of an adhesive member that adheres a display panel and a window member to each other are improved.

[0006] Embodiments of the present disclosure also provide an apparatus for manufacturing a display device and a method for manufacturing a display device, in which process efficiency and productivity are improved.

[0007] However, embodiments of the present disclosure are not limited to those set forth herein. The above and other features of embodiments of the present disclosure will become more apparent to one of ordinary skill in the art to which the present disclosure belongs by referencing the detailed description of the present disclosure given below.

[0008] According to an embodiment of the present disclosure, an apparatus for manufacturing a display device includes a coating head configured to coat an adhesive material to an object, and a selective solidification module configured to solidify a portion of the adhesive material, wherein the selective solidification module is configured to solidify an edge portion of the adhesive material.

[0009] In an embodiment, the apparatus can further include a transport module including a carrier film and a roller set configured to provide a driving force to the carrier film, wherein the carrier film provides a space in which the object is seated.

[0010] In an embodiment, the coating head and the selective curing module can be located on opposite sides of the carrier film with the carrier film interposed between the coating head and the selective curing module.

[0011] In an embodiment, the carrier film can be a light-transmissive film.

[0012] In an embodiment, the roll set can include an unwinding roll configured to unwind the carrier film and a winding roll configured to wind the carrier film.

[0013] In an embodiment, the selective curing module can include a first curing device configured to irradiate the adhesive material with light, and a light-blocking film that blocks a portion of the light, and the light-blocking film includes a non-transmissive region that blocks a portion of the light, and a transmissive region that transmits a portion of the light through the transmissive region.

[0014] In an embodiment, the light-blocking film can be provided with an aperture through which a portion of the light is transmitted.

[0015] In an embodiment, the object can include a release film, and the alignment mark can be formed on the release film by the adhesive material coated from the coating head.

[0016] In an embodiment, the release film can be a light-transmissive film.

[0017] In an embodiment, the apparatus can further include a first laminating device configured to laminate the display panel on the object to which the adhesive material is coated.

[0018] In an embodiment, the apparatus can further include a second curing device configured to completely cure the adhesive material included in the object to which the display panel is laminated, wherein the second curing device can form the adhesive member by curing the adhesive material.

[0019] In an embodiment, the apparatus can further include a second laminating device configured to laminate a window member on the object including the display panel and the adhesive member.

[0020] In an embodiment, the apparatus can further include a cutting device that cuts an edge portion of the object.

[0021] In an embodiment, the apparatus can further include a film removing device configured to remove the release film disposed on the adhesive member.

[0022] In an embodiment, the adhesive material can include an optically transparent resin having a liquid form.

[0023] According to an embodiment of the disclosure, there is provided a method for manufacturing a display device, the method including: applying an adhesive material to a release film, selectively curing an edge portion of the adhesive material, laminating a display panel on the release film and the adhesive material, forming an adhesive member by curing the entirety of the adhesive material, and removing the release film and laminating a window member on the display panel and the adhesive member.

[0024] In an embodiment, the applying of the adhesive material and the selective curing of the edge portion of the adhesive material can be performed at least partially simultaneously.

[0025] In an embodiment, in laminating the display panel, a portion of the adhesive material other than the selectively cured edge portion can be in a liquid form.

[0026] In an embodiment, the release film can be removed after the entirety of the adhesive material is cured.

[0027] In an embodiment, the method can further include cutting an edge portion of the display panel, the adhesive member, and the release film.

[0028] According to the apparatus for manufacturing a display device and the method for manufacturing a display device according to an embodiment of the disclosure, the adhesive strength and the adhesive reliability of the adhesive member that adheres the display panel and the window member to each other can be improved.

[0029] According to the apparatus for manufacturing a display device and the method for manufacturing a display device according to an embodiment of the disclosure, process efficiency and productivity can be improved.

[0030] Effects of the disclosure are not limited to the aforementioned effects, and various other effects are included in the specification. BRIEF DESCRIPTION OF DRAWINGS

[0031] Embodiments of the disclosure will become more fully understood from the detailed description and accompanying drawings, in which:

[0032] Figure 1 is a perspective view to illustrate a display device according to an embodiment;

[0033] Figure 2 is a cross-sectional view taken along line I-I' of Figure 1

[0034] Figure 3 is a cross-sectional view to illustrate a display panel according to an embodiment;

[0035] Figure 4 and Figure 5 is a cross-sectional view to illustrate an apparatus for manufacturing a display device according to an embodiment;

[0036] ​Figure 6 FIG. 1 is a plan view to illustrate an apparatus for manufacturing a display device in a state in which an adhesive material is applied to a release film according to an embodiment;

[0037] Figure 7 FIG. 2 is a flowchart to illustrate a method for manufacturing a display device according to an embodiment;

[0038] Figure 8 FIG. 3 is a sectional view to illustrate a process S100 of Figure 7 FIG. 4 is a sectional view to illustrate a process S100 of

[0039] Figure 9 FIG. 5 is a sectional view to illustrate a process S100, S200 of Figure 7 FIG. 6 is a sectional view to illustrate a process S100, S200 of

[0040] Figure 10 FIG. 7 is a sectional view to illustrate a process S200 of Figure 7 FIG. 8 is a sectional view to illustrate a process S200 of

[0041] Figure 11 FIG. 9 is a sectional view to illustrate a process S100, S200 of Figure 7 FIG. 10 is a sectional view to illustrate a process S100, S200 of

[0042] Figure 12 FIG. 11 is a sectional view to illustrate a process S200, S300 of Figure 7 FIG. 12 is a sectional view to illustrate a process S200, S300 of

[0043] Figure 13 FIG. 13 is a sectional view to illustrate a process S400 of Figure 7 FIG. 14 is a sectional view to illustrate a process S400 of

[0044] Figure 14 FIG. 15 is a sectional view to illustrate a process S500 of Figure 7 FIG. 16 is a sectional view to illustrate a process S500 of

[0045] Figure 15 FIG. 17 is a sectional view to illustrate a process S600 of Figure 7 FIG. 18 is a sectional view to illustrate a process S600 of

[0046] Figure 16 FIG. 19 is a sectional view to illustrate a portion of a display device in a state in which a window member is laminated on a display panel according to an embodiment. DETAILED DESCRIPTION

[0047] The present disclosure will now be described hereinafter with reference to the accompanying drawings, which show by way of illustration various embodiments of the present disclosure. The present disclosure may, however, be embodied 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 the scope of the present disclosure to those skilled in the art.

[0048] It will also be understood that, when a layer is referred to as being "on" another layer or substrate, it can be directly on the other layer or substrate, or intervening layers can also be present. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements present. Like reference numerals refer to like elements throughout the specification.

[0049] It will be understood that, although the terms "first," "second," "third," etc. can be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms are simply used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, "a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings herein.

[0050] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the terms "a," "an," and "at least one" do not denote a limitation of quantity, and are intended to cover both the singular and plural forms. Thus, the use of "a," "an," or "at least one" in referring to an element is intended to mean that one or more of the elements are present. For example, "a" element has the same meaning as "at least one" element, unless the context clearly indicates otherwise. "At least one" is not to be construed as limiting to "one." "Or" means "and / or." As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, components, and / or groups thereof, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and / or groups thereof.

[0051] In addition, relative terms such as "lower" or "bottom" and "upper" or "top," can be used herein to describe one element's or portion's relationship to another element or portion as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in one or more of the figures is turned over, elements described as being on the "lower" side of other elements would then be oriented on "upper" sides of the other elements. The term "lower" encompasses both an "lower" and "upper" orientation. Likewise, the term "upper" encompasses both an "upper" and "lower" orientation. The terms "upwardly" and "downwardly" can be used herein to describe the relative direction of one element or portion to another element or portion as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in one or more of the figures is turned over, elements described as being "upwardly" disposed with respect to other elements would then be oriented "downwardly" with respect to the other elements. The term "upwardly" encompasses both an "upwardly" and "downwardly" orientation. Likewise, the term "downwardly" encompasses both an "upwardly" and "downwardly" orientation.

[0052] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0053] Embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of ideal embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and / or tolerances, are to be expected. Thus, embodiments described herein are not to be construed as being limited to the particular shapes illustrated herein but include deviations in shapes that result from, for example, manufacturing. For example, an illustrated region typically can have a rough and / or nonlinear shape. In addition, an illustrated sharp corner can be rounded. Thus, the regions illustrated in the figures are schematic and their shapes are not intended to illustrate the precise shape of a region and are not intended to limit the scope of the present claims.

[0054] Embodiments of the present disclosure are described in detail below with reference to the attached drawings.

[0055] Figure 1 A perspective view of a display device according to an embodiment is illustrated. Figure 2 A cross-sectional view taken along line I-I' of Figure 1

[0056] Referring to Figure 1 and Figure 2 , a display device DD according to an embodiment can refer to any electronic device provided with a display screen. The display device DD can display moving images or still images. For example, a television, a laptop computer, a monitor, a billboard, an Internet of Things (IoT) device, a mobile phone, a smart phone, a tablet Personal Computer (PC), an electronic watch, a smart watch, a watch phone, a head-mounted display, a mobile communication terminal, an electronic notebook, an electronic book, a Portable Multimedia Player (PMP), a navigation device, a game machine, a digital camera, and a camcorder, etc. provided with a display screen can be included in the display device DD. InThe display device DD illustrated in Figure 1 as an example of a smart phone, but the present disclosure is not limited thereto.

[0057] In an embodiment, as illustrated in Figure 1 , the display device DD can include a display module DM and a case member CAM.

[0058] The display module DM can include a display area. The display area can be an area in which the image IM is displayed. The display area can include a main display area DA0, and first to fourth sub display areas DA1, DA2, DA3, and DA4 adjacent to the main display area DA0, and first to fourth corner display areas EDA1, EDA2, EDA3, and EDA4 adjacent to the main display area DA0.

[0059] The main display area DA0 can be parallel to a plane extending in the first direction DR1 and the second direction DR2. A normal direction of the main display area DA0 (i.e., a thickness direction of the display device DD) can be the third direction DR3.

[0060] In the drawings, the first direction DR1 and the second direction DR2 are respectively a horizontal direction, and intersect each other. For example, the first direction DR1 and the second direction DR2 can be orthogonal to each other. Also, the third direction DR3 can be a vertical direction intersecting, for example, orthogonal to the first direction DR1 and the second direction DR2. The directions indicated by the first to third directions DR1, DR2, and DR3 can be a relative concept, and can be switched to other directions.

[0061] The main display area DA0 can display the image IM through a front surface. In an embodiment, for example, the main display area DA0 can display the image IM toward the third direction DR3. The image IM can include a still image and a dynamic image. In an embodiment, for example, as shown in FIG. 1A, the image IM can include a viewing window and an icon. Figure 1

[0062] The first sub display area DA1 can be adjacent to the main display area DA0 on one side in the second direction DR2. The first sub display area DA1 can display the image IM in a direction intersecting the third direction DR3 which is a thickness direction of the display device DD. In an embodiment, for example, in a case where an angle formed by the main display area DA0 and the first sub display area DA1 is 90°, the direction intersecting the third direction DR3 can be on one side in the second direction DR2.

[0063] The second sub display area DA2 can be adjacent to the main display area DA0 on the other side in the first direction DR1. The second sub display area DA2 can display the image IM in a direction intersecting the third direction DR3. In an embodiment, for example, in a case where an angle formed by the main display area DA0 and the second sub display area DA2 is 90°, the direction intersecting the third direction DR3 can be on the other side in the first direction DR1.

[0064] ​The third sub-display area DA3 can be adjacent to the main display area DA0 on the other side in the second direction DR2. The third sub-display area DA3 can display the image IM in a direction intersecting the third direction DR3. In an embodiment, for example, in a case where an angle formed by the main display area DA0 and the third sub-display area DA3 is 90°, the direction intersecting the third direction DR3 can be on the other side in the second direction DR2.

[0065] The fourth sub-display area DA4 can be adjacent to the main display area DA0 on one side in the first direction DR1. The fourth sub-display area DA4 can display the image IM in a direction intersecting the third direction DR3. In an embodiment, for example, in a case where an angle formed by the main display area DA0 and the fourth sub-display area DA4 is 90°, the direction intersecting the third direction DR3 can be on one side in the first direction DR1.

[0066] The first corner display area EDA1 can be located between the first sub-display area DA1 and the second sub-display area DA2. The first corner display area EDA1 can display the image IM in a direction intersecting a thickness direction DR3 of the display device DD. In an embodiment, for example, in a case where an angle formed by the main display area DA0 and the first corner display area EDA1 is 90°, the direction intersecting the thickness direction DR3 can be at least one direction between the first direction DR1 and the second direction DR2. In another embodiment, the angle formed by the main display area DA0 and the first corner display area EDA1 can be greater than or less than 90°.

[0067] The second corner display area EDA2 can be located between the second sub-display area DA2 and the third sub-display area DA3. The second corner display area EDA2 can display the image IM in a direction intersecting the thickness direction DR3 of the display device DD. In an embodiment, for example, in a case where an angle formed by the main display area DA0 and the second corner display area EDA2 is 90°, the direction intersecting the thickness direction DR3 can be at least one direction between the first direction DR1 and the second direction DR2. In another embodiment, the angle formed by the main display area DA0 and the second corner display area EDA2 can be greater than or less than 90°.

[0068] The third corner display area EDA3 can be located between the third sub display area DA3 and the fourth sub display area DA4. The third corner display area EDA3 can display the image IM in a direction intersecting the thickness direction DR3 of the display device DD. In an embodiment, for example, in a case where an angle formed by the main display area DA0 and the third corner display area EDA3 is 90°, the direction intersecting the thickness direction DR3 can be at least one direction between the first direction DR1 and the second direction DR2. In another embodiment, the angle formed by the main display area DA0 and the third corner display area EDA3 can be greater than or less than 90°.

[0069] The fourth corner display area EDA4 can be located between the fourth sub display area DA4 and the first sub display area DA1. The fourth corner display area EDA4 can display the image IM in a direction intersecting the thickness direction DR3 of the display device DD. In an embodiment, for example, in a case where an angle formed by the main display area DA0 and the fourth corner display area EDA4 is 90°, the direction intersecting the thickness direction DR3 can be at least one direction between the first direction DR1 and the second direction DR2. In another embodiment, the angle formed by the main display area DA0 and the fourth corner display area EDA4 can be greater than or less than 90°.

[0070] The main display area DA0 can be partially or completely surrounded by the first to fourth sub display areas DA1, DA2, DA3, and DA4 and the first to fourth corner display areas EDA1, EDA2, EDA3, and EDA4.

[0071] In an embodiment, as shown in FIG. 1A, the display module DM can include a display panel DP, an adhesive member ADH, and a window member WM. Figure 2

[0072] The display panel DP can include a light emitting display panel. The light emitting display panel can be, for example, an organic light emitting display panel or a quantum dot light emitting display panel. The light emitting layer of the organic light emitting display panel can include an organic light emitting material. The light emitting layer of the quantum dot light emitting display panel can include quantum dots and quantum rods, etc. This is an example, and in the present disclosure, the display panel DP is not particularly limited. In an embodiment, the display panel DP can be an organic light emitting display panel, which will be described later with reference to FIG. 2. Figure 3 The description is made by way of example.

[0073] ​An adhesive member ADH can be disposed between the display panel DP and the window member WM. The adhesive member ADH can adhere the display panel DP and the window member WM to each other. The adhesive member ADH can include a general adhesive. In an embodiment, for example, the adhesive member ADH can include a pressure sensitive adhesive (PSA), an optical clear adhesive (OCA), or an optical clear resin (OCR). The adhesive member ADH can be formed by the apparatus 10 (see Figure 4 ) for manufacturing the display device described later.

[0074] The window member WM can be disposed on the adhesive member ADH. The window member WM can cover the display panel DP. The window member WM can completely cover the main display area DA0, the first to fourth sub display areas DA1, DA2, DA3, and DA4, and the first to fourth corner display areas EDA1, EDA2, EDA3, and EDA4 of the display device DD. The shape of the display panel DP can correspond to the shape of the window member WM. The window member WM can protect the display panel DP from external impact and provide an input surface to a user.

[0075] The window member WM can have a transparent property so that light generated from the display panel DP can be transmitted from the window member WM. The window member WM can include a glass material or a plastic material. In some embodiments, in the case where the window member WM includes glass, the window member WM can include chemically ion exchanged tempered glass. In another embodiment, in the case where the window member WM includes plastic, the window member WM can include a polyimide (PI) film.

[0076] The case member CAM can be disposed under the display module DM, and the case member CAM can have a predetermined color, but is not limited thereto. The case member CAM can be disposed at the outermost portion of the display device DD, and can accommodate components in the case member CAM. The case member CAM can include a bottom surface and a sidewall extending from the bottom surface. Further, an electronic module (not illustrated) can be accommodated in an internal space defined by the bottom surface and the sidewall.

[0077] The electronic module can include, for example, a camera, a flash, a fingerprint sensor, a battery, and a function sensor. The function sensor can include a proximity sensor, a color density detection sensor, an illuminance sensor, a motion sensor, or a heartbeat sensor, etc. However, this is an example, and the function sensor is not limited to the above-described example. Further, some of the camera, the flash, the fingerprint sensor, the battery, and the function sensor can be omitted, and other electronic modules can be further disposed.

[0078] The case member CAM can include a material having relatively high rigidity than that of the display module DM. In an embodiment, for example, the case member CAM can include a plurality of frames and / or plates made of glass, plastic, metal, or a combination thereof. The case member CAM can stably protect components of the display device DD from external impact.

[0079] Figure 3 A cross-sectional view of a display panel according to an embodiment is illustrated.

[0080] Referring to Figure 3 An embodiment of the display panel DP can include a substrate layer SUB, a circuit element layer ML, a display element layer IML, a thin film encapsulation layer TFE, and a touch sensor layer ISL. The circuit element layer ML, the display element layer IML, the thin film encapsulation layer TFE, and the touch sensor layer ISL can be sequentially disposed on the substrate layer SUB.

[0081] The substrate layer SUB can include a transparent material. In an embodiment, for example, the substrate layer SUB can include a transparent insulating material such as glass or quartz. The substrate layer SUB can be a rigid substrate. However, the substrate layer SUB is not limited thereto, and can include plastic such as polyimide, and can have a flexible property that can be bent, folded, or curled.

[0082] The circuit element layer ML can include a buffer film BFL as an inorganic film, a first intermediate inorganic film GI and a second intermediate inorganic film ILD, and an intermediate organic film PSV as an organic film. The materials of the inorganic film and the organic film are not particularly limited, and in an embodiment, the buffer film BFL can be optionally disposed or omitted.

[0083] A semiconductor pattern OSP1 of the transistor T1 can be disposed on the buffer film BFL. The semiconductor pattern OSP1 can be selected from amorphous silicon, polysilicon, or metal oxide semiconductor.

[0084] The first intermediate inorganic film GI can be disposed on the semiconductor pattern OSP1. A control electrode GE1 of the transistor T1 can be disposed on the first intermediate inorganic film GI.

[0085] A second intermediate inorganic film ILD covering the control electrode GE1 can be disposed on the first intermediate inorganic film GI. An input electrode DE1 and an output electrode SE1 of the transistor T1 can be disposed on the second intermediate inorganic film ILD.

[0086] The input electrode DE1 and the output electrode SE1 can be connected to the semiconductor pattern OSP1 through a first via CH1 and a second via CH2, respectively, which are defined or formed through the first intermediate inorganic film GI and the second intermediate inorganic film ILD. In another embodiment, the transistor T1 can be modified to have a bottom gate structure.

[0087] An intermediate organic film PSV covering the input electrode DE1 and the output electrode SE1 can be disposed on the second intermediate inorganic film ILD. The intermediate organic film PSV can provide a flat surface.

[0088] A display element layer IML can be disposed on the intermediate organic film PSV. The display element layer IML can include a pixel definition film PDL and an organic light emitting diode OLED. The pixel definition film PDL can include an organic material. A first electrode AE can be disposed on the intermediate organic film PSV. The first electrode AE can be connected to the output electrode SE1 through a third via hole CH3 defined or formed through the intermediate organic film PSV. An open hole OP can be defined in the pixel definition film PDL. The open hole OP can expose at least a portion of the first electrode AE. In an embodiment, the pixel definition film PDL can be omitted.

[0089] In an embodiment, the emission area PXA can partially overlap the transistor T1.

[0090] A hole control layer HCL can be commonly disposed in the emission area PXA and the non-emission area NPXA. An emission layer EML can be disposed on the hole control layer HCL. The emission layer EML can be disposed in an area corresponding to the open hole OP. The emission layer EML can include an organic material and / or an inorganic material. The emission layer EML can generate a predetermined color light.

[0091] An electron control layer ECL can be disposed on the emission layer EML. A second electrode CE can be disposed on the electron control layer ECL.

[0092] A thin film encapsulation layer TFE can be disposed on the second electrode CE. The thin film encapsulation layer TFE can cover the second electrode CE. In an embodiment, a capping layer (not illustrated) covering the second electrode CE can be further disposed between the thin film encapsulation layer TFE and the second electrode CE. In such an embodiment, the thin film encapsulation layer TFE can directly cover the capping layer (not illustrated).

[0093] A touch sensor layer ISL can be disposed on the thin film encapsulation layer TFE. The touch sensor layer ISL can be directly disposed on the thin film encapsulation layer TFE and embedded in the display panel DP. The touch sensor layer ISL can include a plurality of touch electrodes for capacitively sensing a touch of a user and a touch line connecting the plurality of touch electrodes and a touch driver to each other. In an embodiment, for example, the touch sensor layer ISL can sense a touch of a user in a mutual capacitance manner or a self-capacitance manner. In another embodiment, the touch sensor layer ISL can be disposed on the thin film encapsulation layer TFE in the form of a separate substrate.

[0094] Hereinafter, an embodiment of an apparatus 10 (see Figure 4 ) for manufacturing a display device that forms an adhesive member ADH on a display panel DP of a display device DD and laminates a window member WM on the display panel DP and the adhesive member ADH will be described.

[0095] Figure 4 and Figure 5 is a cross-sectional view to illustrate an apparatus for manufacturing a display device according to an embodiment. Figure 6 is a plan view to illustrate an apparatus for manufacturing a display device in a state in which an adhesive material is applied to a release film according to an embodiment.

[0096] Referring to Figures 1-3 in addition to Figures 4-6 , an embodiment of an apparatus 10 for manufacturing a display device can form an adhesive member ADH on a display panel DP and laminate a window member WM on the display panel DP and the adhesive member ADH. The apparatus 10 for manufacturing a display device can perform an application process and a curing process of an adhesive material OCR and a lamination process of a window member WM.

[0097] The apparatus 10 for manufacturing a display device can apply an adhesive material OCR to a release film RF. The apparatus 10 for manufacturing a display device can selectively cure a portion of the adhesive material OCR and then laminate a display panel DP on the selectively cured adhesive material OCR and the release film RF. The apparatus 10 for manufacturing a display device can form an adhesive member ADH by curing the entire selectively curable adhesive material OCR. The apparatus 10 for manufacturing a display device can cut a portion of the display panel DP, the adhesive member ADH, and the release film RF. The apparatus 10 for manufacturing a display device can remove the release film RF and laminate a window member WM on the display panel DP and the adhesive member ADH.

[0098] The apparatus 10 for manufacturing a display device can include a transport module 100, an application head 200, a selective curing module 300, a first lamination device 400, a second curing device 500, a cutting device 600, and a second lamination device 700.

[0099] The transport module 100 can transport an object SB disposed thereon. The release film RF can be the object SB before laminating the display panel DP, and the display panel DP can be the object SB after laminating the display panel DP.

[0100] The transport module 100 can be a roll-to-roll apparatus. In an embodiment, for example, the transport module 100 can include a carrier film 110 and a roller set 120. The transport module 100 can transport the object SB by placing the object SB on the carrier film 110 that moves by unwinding and winding of the roller set 120. The apparatus 10 for manufacturing a display device according to an embodiment can perform a continuous process by a roll-to-roll process, and thus process efficiency and productivity can be improved.

[0101] The carrier film 110 can move by a driving force generated by the roller set 120. That is, the roller set 120 can provide the driving force to the carrier film 110. The carrier film 110 can transport the object SB while moving by the driving force generated by the roller set 120.

[0102] The carrier film 110 can provide a space in which the object SB can be placed. In an embodiment, for example, the object SB can be placed on an upper surface of the carrier film 110. When the object SB is placed, the carrier film 110 can be disposed between the object SB and the first curing device 310, which will be described later.

[0103] In some embodiments, the carrier film 110 can be a light-transmissive film. Since the carrier film 110 is disposed between the object SB and the first curing device 310, the carrier film 110 can transmit light radiated from the first curing device 310 through the carrier film 110 so that the light can reach the object SB. Similarly, the release film RF can also be a light-transmissive film.

[0104] The roller set 120 can include at least one roller. In an embodiment, for example, the roller set 120 can include an unwinding roller 121, a winding roller 122, and a direction changing roller 123.

[0105] The unwinding roller 121 can rotate in at least one direction. The unwinding roller 121 can unwind the carrier film 110 while rotating in at least one direction. The unwinding roller 121 can generate a driving force so that the carrier film 110 can be unwound.

[0106] The winding roller 122 can rotate in at least one direction. The winding roller 122 can wind the carrier film 110 while rotating in at least one direction. The winding roller 122 can generate a driving force so that the carrier film 110 can be wound.

[0107] In an embodiment, as exemplified in Figure 4 and Figure 5 the rotation direction of the winding roller 122 and the rotation direction of the unwinding roller 121 can be the same as each other, but the present disclosure is not limited thereto, and the unwinding roller 121 and the winding roller 122 can also rotate in opposite directions.

[0108] In some embodiments, both the unwinding roller 121 and the winding roller 122 can generate a driving force. However, the present disclosure is not limited thereto, and only one of the unwinding roller 121 and the winding roller 122 can generate a driving force, and the other of the unwinding roller 121 and the winding roller 122 can rotate together by the driving force.

[0109] The direction changing roller 123 can change the moving direction of the carrier film 110. In an embodiment, for example, as illustrated in Figure 4 and Figure 5 , the direction changing roller 123 can change the moving direction of the carrier film 110 so that the carrier film 110, which has moved in a horizontal direction, moves in a diagonal direction. In an embodiment, as illustrated in Figure 4 and Figure 5 , the number of the direction changing roller 123 can be one, but the present disclosure is not limited thereto. In another embodiment, the direction changing roller 123 can also be omitted, or two or more direction changing rollers 123 can also be included.

[0110] In some embodiments, the direction changing roller 123 can rotate together by the driving force generated by at least one of the unwinding roller 121 and the winding roller 122. However, the present disclosure is not limited thereto, and the direction changing roller 123 can also generate a driving force.

[0111] The application head 200 can apply the ink I to the object SB. In an embodiment, for example, the application head 200 can apply the ink I to the release film RF. In some embodiments, the application head 200 can include an inkjet printing device and a dispensing device.

[0112] The ink I can include an adhesive material OCR. In some embodiments, the adhesive material OCR can include a liquid optically clear resin (OCR).

[0113] As illustrated in Figure 6 , the adhesive material OCR can correspond to the shape of the display device DD (see Figure 1 ). In some embodiments, the adhesive material OCR can include an edge portion PA located at an edge and a center portion MA surrounded by the edge portion PA. In an embodiment in which the adhesive material OCR is in a liquid form, the edge portion PA of the adhesive material OCR can include an inclined surface inclined toward an outward direction due to the dispersibility of the adhesive material OCR.

[0114] In some embodiments, the coating head 200 can coat an alignment mark MRK to the release film RF. That is, the alignment mark MRK can be formed on the release film RF by the adhesive material OCR coated from the coating head 200. The alignment mark MRK can be disposed in an area other than the area in which the central portion MA and the edge portion PA are disposed on the release film RF. The apparatus 10 for manufacturing a display device according to an embodiment can improve the alignment accuracy during a lamination process of the display panel DP by coating the alignment mark MRK. Further, because the alignment mark MRK is coated along with the coating of the central portion MA and the edge portion PA of the adhesive material OCR, a separate process for forming the mark can not be additionally performed, and thus the process time can be shortened.

[0115] The selective curing module 300 can selectively cure a portion of the adhesive material OCR. In an embodiment, for example, as exemplified in Figure 6 the selective curing module 300 can selectively cure the edge portion PA of the adhesive material OCR, and can not cure the central portion MA of the adhesive material OCR.

[0116] In some embodiments, the selective curing module 300 can include a first curing device 310 and a light blocking film 320.

[0117] The first curing device 310 can irradiate the adhesive material OCR with light. In an embodiment, for example, the first curing device 310 can irradiate the adhesive material OCR with ultraviolet light, but is not limited thereto. The first curing device 310 can cure the adhesive material OCR by irradiating the adhesive material OCR with light.

[0118] The light blocking film 320 can block at least some (or at least a portion) of the light generated by the first curing device 310. The light blocking film 320 can transmit at least some of the light generated by the first curing device 310 through the light blocking film 320. In an embodiment, as exemplified in Figure 4 the light blocking film 320 can be provided with an opening 320a. In such an embodiment, the light blocking film 320 can transmit at least some of the light generated by the first curing device 310 that passes through the opening 320a, and can block at least some of the light generated by the first curing device 310 that passes through a portion of the light blocking film 320 other than the opening 320a.

[0119] However, the light blocking film 320 is not limited thereto, and can include a transmissive region that transmits a portion of light therethrough, and a non-transmissive region that blocks a portion of light, instead of the aperture 320a and a portion of the light blocking film 320 other than the aperture. In an embodiment, for example, the aperture is not defined through the light blocking film 320, and the light blocking film 320 can transmit at least some of the light generated by the first curing device 310 through the transmissive region of the light blocking film 320, and block at least some of the light generated by the first curing device 310 through the non-transmissive region of the light blocking film 320.

[0120] When moving by the carrier film 110, the edge portion PA of the adhesive material OCR can overlap the aperture 320a or the transmissive region of the light blocking film 320 at a certain point in time. At the point in time at which the edge portion PA of the adhesive material OCR and the aperture 320a or the transmissive region of the light blocking film 320 overlap each other, the first curing device 310 can irradiate the adhesive material OCR with light, that is, irradiate or emit light to the adhesive material OCR. Accordingly, a portion of the adhesive material OCR, for example, the edge portion PA, can be selectively cured. After the selective curing process, the edge portion PA can include a solid post-cured adhesive material OCR_B (i.e., a portion of the adhesive material in a solid state), and the center portion MA can include a liquid pre-cured adhesive material OCR_A (i.e., a portion of the adhesive material in a liquid state).

[0121] The apparatus 10 for manufacturing a display device according to an embodiment can easily control the shape of the adhesive member ADH by selectively curing the edge portion PA of the adhesive material OCR. In an embodiment, for example, as time increases from a point in time after the liquid adhesive material OCR is applied to a point in time before the liquid adhesive material OCR is cured, an area occupied by the inclined surface of the edge portion PA can increase due to the dispersibility of the adhesive material OCR. Accordingly, once the adhesive material OCR is applied, by selectively curing the edge portion PA, the inclined surface of the edge portion PA can be effectively prevented from spreading before a lamination process of the display panel DP and a lamination process of the window member WM, which will be described later, are performed.

[0122] Further, by selectively curing the edge portion PA of the adhesive material OCR while maintaining the center portion MA of the adhesive material OCR in a liquid form, the surface quality of a lamination surface between the display panel DP and the adhesive material OCR in a subsequent lamination process of the display panel DP can be improved.

[0123] In the apparatus 10 for manufacturing a display device according to an embodiment, as Figure 4For example, the coating head 200 and the selective curing module 300 can be located at opposite sides of the carrier film 110 with the carrier film 110 interposed between the coating head 200 and the selective curing module 300. Accordingly, a horizontal distance between the coating head 200 and the first curing device 310 or a horizontal distance D1 between the coating head 200 and the aperture 320a of the light blocking film 320 can be minimized. Thus, by minimizing a time between the coating process and the selective curing process, a shape of the edge portion PA can be easily controlled.

[0124] The first laminating device 400 can laminate the display panel DP on the release film RF and the adhesive material OCR. In an embodiment, as Figure 4 For example, the first laminating device 400 can be a roll laminating device, but the present disclosure is not limited thereto. In an embodiment, for example, the first laminating device 400 can be a vacuum laminating device.

[0125] The second curing device 500 can cure the adhesive material OCR to form the adhesive member ADH. In an embodiment, the second curing device 500 can irradiate the adhesive material OCR with light. In an embodiment, for example, the second curing device 500 can irradiate the adhesive material OCR with ultraviolet light, but is not limited thereto.

[0126] The second curing device 500 can completely cure the adhesive material OCR included in the object SB on which the display panel DP is laminated. In an embodiment, for example, the second curing device 500 can completely cure the adhesive material OCR without distinguishing the center portion MA and the edge portion PA of the adhesive material OCR. The uncured center portion MA can be cured to change from a liquid form to a solid form, and the edge portion PA that has been selectively cured can have no change in state or can have an increased degree of curing. The adhesive member ADH can be formed by curing the adhesive material OCR.

[0127] The selective curing process of the first curing device 310 can be referred to as temporary curing, and the curing process of the second curing device 500 can be referred to as main curing, but the present disclosure is not limited thereto.

[0128] In an embodiment, as Figure 5 For example, the second curing device 500 can cure the adhesive material OCR by irradiating the adhesive material OCR with light, but the present disclosure is not limited thereto. In an embodiment, the second curing device 500 completely cures the adhesive material OCR, and thus can cure the adhesive material OCR by thermal curing or natural curing as well as by ultraviolet (UV) curing.

[0129] In the apparatus 10 for manufacturing a display device according to one embodiment, the primary curing of the adhesive material OCR by the second curing device 500 can be performed while the adhesive material OCR is covered by the release film RF. Accordingly, the area of ​​the adhesive material OCR in contact with oxygen can be minimized, and the non-curing phenomenon or reduced curing degree of the adhesive material OCR due to the oxygen inhibition effect can be effectively prevented.

[0130] In the apparatus 10 for manufacturing a display device according to one embodiment, the primary curing of the adhesive material OCR can be performed by a second curing device 500 before the laminated window member WM. As the degree of curing of the adhesive material OCR increases, the adhesive strength of the adhesive material OCR or the adhesive member ADH can be improved. Because the primary curing of the adhesive material OCR is performed before the laminated window member WM, the adhesive strength of the adhesive member ADH to the window member WM can be improved.

[0131] The cutting device 600 can cut the edge portions of the adhesive member ADH. The edge portions of the adhesive member ADH, including the inclined surface of the aforementioned adhesive material OCR, can be removed by the cutting device 600. The edge portions of the display panel DP and the release film RF can also be removed together with the edge portions of the adhesive member ADH. In some embodiments, the cutting process of the cutting device 600 can be omitted.

[0132] In one embodiment, such as Figure 5 As illustrated, the cutting device 600 can irradiate the display panel DP, the adhesive component ADH, and the release film RF with a laser beam LS. The cutting device 600 can be a laser cutting device. However, the cutting device 600 is not limited to this and can include various cutting devices, such as blade cutting devices and water jet cutting devices.

[0133] In one embodiment, although in Figure 5 As illustrated, however, the apparatus 10 for manufacturing the display device may further include a film removal device 650 for removing the release film RF disposed on the adhesive member ADH prior to the lamination process of the window member WM by the second lamination device 700. The release film RF can be removed prior to the lamination process of the window member WM. In this document, it will be understood that the film removal device is a conventional film removal device for removing the release film, and for ease of description, any detailed structure, i.e., conventional features, will be omitted.

[0134] The second lamination device 700 can laminate the window member WM onto the display panel DP and the adhesive member ADH. In one embodiment, as... Figure 5 As illustrated, the second laminating device 700 may be a rolling laminating device, but this disclosure is not limited thereto. In one embodiment, for example, the second laminating device 700 may be a vacuum laminating device.

[0135] The apparatus 10 for manufacturing a display device according to an embodiment can improve process efficiency and productivity by coating the adhesive material OCR to the release film RF through a roll-to-roll process.

[0136] In a conventional method of coating the adhesive material OCR directly to the display panel DP, the adhesive member ADH can be formed by loading to a stage, plasma treatment, alignment with the coating head 200, coating, curing, and unloading.

[0137] According to the apparatus 10 for manufacturing a display device according to an embodiment, in the case of coating the adhesive material OCR to the release film RF, it can not be desirable to precisely align the release film RF with the coating head 200 as in the case of coating the adhesive material OCR directly to the display panel DP. Since the alignment mark MRK is coated to the release film RF as described above, it is only desirable to align the release film RF and the display panel DP with each other when the display panel DP is laminated on the release film RF, and it can not be desirable to precisely align the release film RF with the coating head 200. Accordingly, the alignment process time can be shortened.

[0138] In an embodiment, when the adhesive material OCR is coated to the release film RF, it can not be desirable to improve the adhesive strength between the adhesive material OCR and the coating surface through plasma treatment, and thus, the plasma treatment process can also be omitted. In such an embodiment, since a roll-to-roll process is used, a continuous process is possible, so that the loading process and the unloading process can also be shortened.

[0139] In the case of using an existing solid optical clear adhesive (OCA), the time of a preparation process for a process such as a reinstallation stage, a process of resetting alignment, and a process of resetting the application range of each type of display device DD as a production object can increase. According to the apparatus 10 for manufacturing a display device according to an embodiment, since a release film RF as a standard is used, the preparation process such as a process of a reinstallation stage and a process of resetting alignment can be omitted, and only a process of resetting the application range is performed, so that the preparation time for each type of display device DD can be shortened.

[0140] In addition, it is also possible to minimize facility construction and equipment costs by shortening or omitting the above processes.

[0141] Hereinafter, a method for manufacturing a display device according to an embodiment will be described.

[0142] Figure 7 To illustrate a flowchart of a method for manufacturing a display device according to an embodiment. Figure 8 To illustrate Figure 7a cross-sectional view of the process S100. Figure 9 to illustrate Figure 7 a cross-sectional view of the processes S100, S200. Figure 10 to illustrate Figure 7 a cross-sectional view of the process S200. Figure 11 to illustrate Figure 7 a cross-sectional view of the processes S100, S200. Figure 12 to illustrate Figure 7 a cross-sectional view of the processes S200, S300. Figure 13 to illustrate Figure 7 a cross-sectional view of the process S400. Figure 14 to illustrate Figure 7 a cross-sectional view of the process S500. Figure 15 to illustrate Figure 7 a cross-sectional view of the process S600. Figure 16 to illustrate a cross-sectional view of a portion of a display device in a state in which a window member is laminated on a display panel according to an embodiment.

[0143] Referring to Figures 7-16 , a method S1 of manufacturing a display device according to an embodiment can include applying an adhesive material to a release film (S100), selectively curing an edge portion of the adhesive material (S200), laminating a display panel on the release film and the adhesive material (S300), forming an adhesive member by curing an entirety (or an entire portion) of the adhesive material (S400), cutting an edge portion of the display panel, the adhesive member, and the release film (S500), and removing the release film and laminating a window member on the display panel and the adhesive member (S600).

[0144] As illustrated in Figure 8 , in the process of applying the adhesive material to the release film (S100), the application head 200 can apply the ink I to the first object SB1. The ink I can include the pre-cured adhesive material OCR_A having a liquid form. The first object SB1 can include the release film RF.

[0145] The release film RF can be moved in one direction by the carrier film 110, and the application head 200 can apply the adhesive material OCR to the release film RF.

[0146] As illustrated in Figure 9 and Figure 10 , in the process of selectively curing the edge portion of the adhesive material (S200), the selective curing module 300 can selectively cure a portion of the adhesive material OCR of the first object SB1.

[0147] When the edge portion PA of the adhesive material OCR of the first object SB1 overlaps the opening 320a or the transmission region of the light blocking film 320, the first curing device 310 can cure the pre-cured adhesive material OCR_A of the edge portion PA by irradiating the pre-cured adhesive material OCR_A with light to generate a post-cured adhesive material OCR_B.

[0148] In some embodiments, as exemplified in Figure 9 by disposing the coating head 200 and the first curing device 310 such that the horizontal distance between the coating head 200 and the first curing device 310 is minimized, the coating process S100 for the first object SB1 and the selective curing process S200 for the first object SB1 can be performed simultaneously. According to the method S1 for manufacturing the display device according to an embodiment, by shortening the time between the coating process S100 and the selective curing process S200, the expansion of the inclined surface of the edge portion PA due to the dispersibility of the liquid adhesive material OCR can be minimized.

[0149] However, the present disclosure is not limited thereto, and the coating process S100 for the first object SB1 and the selective curing process S200 for the first object SB1 can also be performed sequentially.

[0150] In some embodiments, as exemplified in Figure 11 the coating process S100 for the second object SB2 can be performed simultaneously with the selective curing process S200 for the first object SB1. According to the method S1 for manufacturing the display device according to an embodiment, a continuous process can be performed using a release film RF by a roll-to-roll process, so that process efficiency and productivity can be improved.

[0151] As exemplified in Figure 12 In the process of laminating the display panel on the release film and the adhesive material (S300), the first laminating device 400 can laminate the display panel DP on the release film RF and the adhesive material OCR. In an embodiment, for example, the first laminating device 400 can laminate the display panel DP in a roll lamination manner or a vacuum lamination manner.

[0152] In some embodiments, the selective curing process S200 for the second object SB2 can be performed simultaneously with the panel lamination process S300 for the first object SB1.

[0153] As exemplified in Figure 13In an embodiment, the second curing device 500 can cure the adhesive material OCR in the process of forming the adhesive member (S400) by curing the entirety of the adhesive material. In an embodiment, for example, the second curing device 500 can cure the adhesive material OCR using ultraviolet curing, thermal curing, or natural curing.

[0154] Although not illustrated in Figure 13 the panel lamination process S300 for the second object SB2 can be performed simultaneously with the main curing process S400 for the first object SB1.

[0155] As Figure 14 illustrated in the cutting process S500 for the second object SB2 can be performed simultaneously with the window member lamination process S600 for the first object SB1.

[0156] Figure 14 Although not illustrated in the main curing process S400 for the second object SB2 can be performed simultaneously with the cutting process S500 for the first object SB1.

[0157] Figure 15 As illustrated in

[0158] the window member lamination process S600 for the second object SB2 can be performed simultaneously with the cutting process S500 for the first object SB1. Figure 15 According to the method S1 for manufacturing the display device according to an embodiment, as

[0159] illustrated in Figure 16 in a case where the window member WM has a curved shape, delamination of the adhesive member ADH can be minimized.

[0160] In an embodiment, for example, the window member WM can include a flat area FA and a curved area CA. The flat area FA can be located substantially at the center of the window member WM, and the curved area CA can be located substantially at the edge portion of the window member WM.

[0161] According to the method S1 for manufacturing the display device according to an embodiment, the inclined surface at the edge portion PA of the adhesive material OCR is removed through a cutting process or minimized through a selective curing process, and thus the thickness TH2 of the adhesive member ADH in the edge region of the adhesive member ADH overlapping the curved region CA and the thickness TH1 of the adhesive member ADH in the central region of the adhesive member ADH overlapping the flat region FA can be substantially the same as each other. Accordingly, delamination of the adhesive member ADH in the region between the display panel DP and the window member WM overlapping the curved region CA can be minimized.

[0162] Further, the main curing is performed before laminating the window member WM and in a state in which the release film RF is attached, so that a curing degree reduction phenomenon due to an oxygen inhibition effect is minimized, and thus the adhesive strength of the adhesive member ADH can be improved. Accordingly, even when the window member WM including the curved region CA is laminated on the adhesive member ADH, delamination of the adhesive member ADH can be minimized.

[0163] The present disclosure should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present disclosure will be thorough and complete, and will fully convey the concept of the present disclosure to those skilled in the art.

[0164] While the present disclosure has been particularly shown and described with reference to embodiments thereof, it will be understood by those skilled in the art that various changes in form and details can be made therein without departing from the spirit or scope of the present disclosure as defined by the claims.

Claims

1. An apparatus for manufacturing a display device, characterized by comprising: The apparatus includes: a coating head configured to coat an object with an adhesive material; and a selective curing module configured to cure a portion of the adhesive material, 2. The apparatus for manufacturing a display device according to claim 1, wherein wherein the selective curing module is configured to cure an edge portion of the adhesive material. further comprising a transport module including a carrier film and a roller set configured to provide a driving force to the carrier film, 3. The apparatus for manufacturing a display device according to claim 2, wherein wherein the carrier film provides a space in which the object is disposed. The coating head and the selective curing module are located on opposite sides of the carrier film with the carrier film interposed therebetween, 4. The apparatus for manufacturing a display device according to claim 2, wherein wherein the carrier film is a light-transmissive film. The roller set includes an unwinding roller configured to unwind the carrier film and a winding roller configured to wind the carrier film. 5.The apparatus for manufacturing a display device of claim 1, wherein the selective curing module includes: a first curing device configured to irradiate the adhesive material with light; and a light-blocking film that blocks a portion of the light, and the light-blocking film includes: a non-transmissive region that blocks a portion of the light; and a transmissive region that transmits a portion of the light therethrough, or wherein the light-blocking film is provided with an aperture through which a portion of the light is transmitted. 6.The apparatus for manufacturing a display device of claim 1, wherein the object includes a release film, and an alignment mark is formed on the release film by the adhesive material coated from the coating head, 7. The apparatus for manufacturing a display device according to claim 1, wherein wherein the release film is a light-transmissive film. further comprising: a first laminating device configured to laminate a display panel on the object to which the adhesive material is coated; a second curing device configured to completely cure the adhesive material included in the object to which the display panel is laminated, 8. The apparatus for manufacturing a display device according to claim 7, wherein wherein the second curing device forms an adhesive member by curing the adhesive material. further comprising: a second laminating device configured to laminate a window member on the object including the display panel and the adhesive member; a cutting device configured to cut an edge portion of the object. 9.The apparatus for manufacturing a display device of claim 7, wherein the object includes a release film, and 10. The apparatus for manufacturing a display device according to claim 1, wherein the apparatus further includes a film removing device configured to remove the release film disposed on the adhesive member. The adhesive material includes an optically transparent resin having a liquid form.

Images