Curved display device and method for manufacturing same

Abstract

A curved display device and a method for manufacturing same are provided. The curved display device according to an embodiment includes a substrate curved to have a preset curvature. The substrate includes an edge part disposed along at least one side of the substrate and a slimming part surrounded by the edge part. The edge part includes a plurality of protruding patterns formed on one surface of the slimming part. A part of the slimming part is disposed between the plurality of protruding patterns.

Description

Curved display device and manufacturing method thereof

[0001] The embodiments relate to a curved display device and a method for manufacturing the same, and more particularly, to a curved display device having a non-uniform slimming portion and a method for manufacturing the same.

[0002] A display device is an electronic device for displaying images. Recently, as technology has advanced, research is being conducted on curved display devices to increase the immersive experience of images.

[0003] Curved display devices provide immersion by bending the surface on which the image is viewed, giving the viewer the feeling of being positioned in space. Conventional curved display devices can be manufactured by making the display panel thinner than a flat display device and then bending it.

[0004] In order to manufacture a curved display device, both the bending stress during the process of bending the flat display device and the space for arranging a masking member to prevent the etchant from penetrating into circuit components on the drive connection film during the process of forming the slimming portion of the display panel must be taken into consideration.

[0005] For example, the border of the display panel includes a protruding pattern, and the protruding pattern is provided with a masking member to prevent the etchant from penetrating into circuit components on the drive connection film during the process of forming the slimming portion of the display panel, and the non-slimming portion formed by the masking member may not be slimmed to maintain outer rigidity, or may be formed to have a lower degree of slimming compared to the slimming portion, which is the image display area.

[0006] In order to prevent the etchant from penetrating into the circuit components on the drive connection film, the area of ​​the masking member must be large, and as the area of ​​the masking member increases, the area of ​​the protruding pattern may increase.

[0007] However, as the area of ​​the protruding pattern increases, the bending stress increases proportionally during the process of bending the flat display device, making it difficult to manufacture a curved display device with a small curvature (R).

[0008] The problem that the present invention seeks to solve is to provide a method for manufacturing a curved display device in which a specific pattern is formed on one side of the display device in order to curve the display device.

[0009] In addition, the problem to be solved by the present invention is to provide a structure of a display device that prevents damage to the display device when the display device is curved by forming a protruding pattern on a part of the display device.

[0010] In addition, the problem to be solved by the present invention is to provide a structure of a display device that can reduce bending stress of the display device by protecting circuit components on a driving connection film from an etchant during the process of slimming a display panel and, at the same time, forming a slimming area that is not slimmed or has a lower degree of slimming compared to a slimming area by arranging a masking member.

[0011] The tasks of the present invention are not limited to the technical tasks mentioned above, and other technical tasks not mentioned will be clearly understood by those skilled in the art from the description below.

[0012] A curved display device according to one embodiment for solving the above problem includes a substrate curved to have a preset curvature, the substrate includes a border portion arranged along at least one side of the substrate, and a slimming portion surrounded by the border portion, the border portion includes a plurality of protruding patterns formed on one surface of the slimming portion, and a portion of the slimming portion is arranged between the plurality of protruding patterns.

[0013] The thickness of the substrate in the above slimming section may be thinner than the thickness of the substrate in the plurality of protruding patterns.

[0014] The above slimming part may include a first slimming part arranged on a display area of ​​the curved display device, and a plurality of second slimming parts arranged on a non-display area of ​​the curved display device, connected to the first slimming part, and arranged between the plurality of protruding patterns.

[0015]

[0016] *The thickness of the substrate in the first slimming section and the thickness of the substrate in the second slimming section may be the same.

[0017] The above plurality of protruding patterns may be circular or polygonal patterns.

[0018] Each of the plurality of protruding patterns may include a first side that is parallel to one side of the substrate and protrudes in the direction of the display area of ​​the curved display device, and two second sides that form a specific angle with the first side.

[0019] The first side and the second side may be perpendicular.

[0020] The width of the protruding pattern is a first length, the spacing between the protruding patterns is a second length, and the first length may decrease and the second length may increase as the distance between the protruding patterns approaches an end.

[0021] The width of the protruding pattern may be a first length, the spacing between the protruding patterns may be a second length, and the pitch, which is the sum of the first length and the second length, may be constant.

[0022] The above first length and the above second length may be different.

[0023] The above-mentioned side of the above-mentioned substrate can correspond to a side curved with the above-mentioned preset curvature.

[0024] The above plurality of protruding patterns can be formed only in the upper area of ​​the TFT substrate of the display device.

[0025] A method for manufacturing a curved display device according to one embodiment includes the steps of preparing a flat display device including a substrate member having a sealing member formed thereon, attaching a release film to one surface of the substrate member, plotting a plurality of protruding patterns on the release film, and removing a portion of the release film.

[0026] The floating step may include a step of floating the plurality of protruding patterns along one side of the substrate member from one end of the substrate member to the other end of the substrate member.

[0027] The floating step may include a step of floating a first side that is parallel to one side of the substrate member and protrudes toward a display area of ​​the display device, and a step of floating a second side that forms a specific angle with the first side.

[0028] The removing step may include removing another portion of the release film closer to the center of the substrate member to leave a portion of the release film attached to the edge of the substrate member.

[0029] According to a display device and a manufacturing method thereof according to one embodiment, the display device can be more easily curved due to a protruding pattern formed on the edge of the curved display device.

[0030] Additionally, the protruding pattern formed on the edge can prevent damage to the driving part of the panel.

[0031] In addition, during the process of slimming the display panel, the circuit components on the driving connection film are protected from the etchant, and at the same time, a masking member is placed to form a slimming area that is not slimmed or is slimmed to a lower degree than the slimming area, thereby providing a structure of a display device that can reduce the bending stress of the display device.

[0032] The effects according to the embodiments are not limited to those exemplified above, and more diverse effects are included in this specification.

[0033] FIG. 1 is a perspective view schematically illustrating a display device according to one embodiment.

[0034] Figure 2 is a cross-sectional view taken along line I1-I1' in the display device of Figure 1.

[0035] Figure 3 is a cross-sectional view taken along line I2-I2' in the display device of Figure 1.

[0036] Figure 4 is an enlarged view of the FF1 portion in Figure 2.

[0037] Fig. 5 is a drawing for explaining the structure of a heteromorphic film including a plurality of protruding patterns.

[0038] Figures 6 to 9 show examples of protrusion patterns.

[0039] Fig. 10 shows a schematic flowchart of a method for manufacturing a curved display device according to one embodiment.

[0040]

[0041] The advantages and features of the present invention, and the methods for achieving them, will become clearer with reference to the embodiments described in detail below together with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but may be implemented in various different forms. These embodiments are provided solely to ensure that the disclosure of the present invention is complete and to fully inform those skilled in the art of the scope of the invention, and the present invention is defined solely by the scope of the claims.

[0042] When elements or layers are referred to as being "on" another element or layer, this includes both directly over the other element or layer and intervening layers or elements. Like reference numerals refer to like elements throughout the specification.

[0043] Although terms like "first" and "second" are used to describe various components, these components are not limited by these terms. These terms are used merely to distinguish one component from another. Therefore, it should be understood that a "first" component referred to below may also be a "second" component within the technical scope of the present invention.

[0044] Hereinafter, specific embodiments will be described with reference to the attached drawings.

[0045] FIG. 1 is a perspective view schematically illustrating a curved display device according to one embodiment.

[0046] Referring to FIG. 1, a curved display device can be interpreted as a curved display device regardless of the main purpose, added function, or name of the device, as long as it includes a display area that displays an image or video. For example, a curved display device may include a small game machine, a large game machine such as a slot machine used in a casino, an electronic whiteboard, an e-book, a smart phone, a mobile phone, a tablet PC, a PDA (Personal Digital Assistant), a PMP (Portable Multimedia Player), a television, a monitor for a personal computer, a laptop computer, an automobile navigation system, an automobile dashboard, a digital camera, a camcorder, an outdoor billboard, an electronic display board, various medical devices, various inspection devices, various home appliances including a display unit such as a refrigerator or a washing machine, an Internet of Things device, etc., but is not limited to the examples described above.

[0047] In one embodiment, the curved display device may have a rectangular shape including two opposing long sides (upper and lower sides when looking at the display surface in the drawing) and two opposing short sides (left and right sides when looking at the display surface in the drawing). With respect to the orientation of a normal display screen, the curved display device may have its long sides arranged horizontally, as illustrated in FIG. 1, but its long sides may also be arranged vertically.

[0048] In the drawing, three directional axes are defined. The first direction (dr1) may be the extension direction of the short side of the curved display device, the second direction (dr2) may be the extension direction of the long side of the curved display device, and the third direction (dr3) may be the thickness direction of the curved display device.

[0049] A curved display device may have a curved shape. That is, the display surface of the curved display device may include a convex or concave curved surface. In one embodiment, the curved display device may include a curved surface formed by bending a second direction axis (long side in the drawing) while maintaining a straight line in a first direction (dr1) axis (short side in the drawing), as illustrated. The second direction (dr2) axis may be bent so as to be concave in a third direction (dr3). That is, the curved surface of the curved display device may include a concave surface that is concavely bent in the display direction when looking at the display surface, as illustrated. The curved display device may be formed by bending a flat display device.

[0050] The curved display device may have a preset curvature. The curved display device may include a substrate that is curved to have the preset curvature.

[0051] The curvature of the curved portion within the curved display device may be constant. That is, the curved portion of the curved display device may be located on a portion (arc) of a circle having a constant radius with respect to its center. The radius of curvature of the curved display device is not limited thereto, but may be 0.5 m to 5 m, or 1 m to 2 m.

[0052] A liquid crystal display (LCD) can be applied as a curved display device. In the following embodiments, a liquid crystal display (LCD) is used as an example of a curved display device, but the curved display device is not limited thereto, and can also be applied to an electrophoretic display (EPD), an organic light emitting diode (OLED), a micro LED display (micro-LED), a plasma display (PDP), a field emission display (FED), a cathode ray tube (CRT), etc.

[0053] A curved display device may include a first substrate (200), a second substrate (300) facing the first substrate (200), and a liquid crystal layer (500) interposed between the first substrate (200) and the second substrate (300). A sealing member (110) is disposed at the edges of the first substrate (200) and the second substrate (300), thereby connecting the first substrate (200) and the second substrate (300) and preventing liquid crystal molecules of the liquid crystal layer ('500' in FIG. 2) from leaking out to the outside.

[0054] The first substrate (200) and the second substrate (300) of the curved display device may both include curved surfaces of the same shape. That is, the curved display device may include a curved first substrate (200) and a curved second substrate (300).

[0055] One of the first substrate (200) and the second substrate (300) may be a thin film transistor substrate, and the other may be a color filter substrate. In this embodiment, a case in which the first substrate (200) is a thin film transistor substrate and the second substrate (300) is a color filter substrate is exemplified. The display direction may be the outer direction of the upper surface of the second substrate (300).

[0056] A first substrate (200), which is a thin film transistor substrate, may protrude relatively to a second substrate (300). For example, one end of the first substrate (200) in the first direction (dr1) may protrude further than one end of the second substrate (300) in the first direction (dr1). At least a portion of a driving unit that drives each pixel of the thin film transistor substrate may be disposed in a non-overlapping portion of the first substrate (200) that protrudes from the second substrate (300). For example, the driving unit may include a driving connection film (410) and a driving circuit board (420) connected thereto, and the driving connection film (410) may be attached to the non-overlapping portion of the first substrate (200). That is, the driving connection film (410) may non-overlap with the second substrate (300).

[0057] Meanwhile, at the protruding portion of the first substrate (200), a first sealant (120) may be placed on the side surface of the second substrate (300), and a second sealant (130) may be placed on the ends of the first substrate (200) and the second substrate (300) where the driving unit is placed. A detailed description of the first sealant (120) and the second sealant (130) will be provided later.

[0058] Although not illustrated in the drawing, the curved display device may further include a polarizing film. The polarizing film may be attached to the back surfaces of the first substrate (200) and the second substrate (300). The attachment area of ​​the polarizing film may be within the etching area described below, but is not limited thereto.

[0059] Hereinafter, the above-described curved display device will be described in more detail with reference to FIGS. 2 to 4.

[0060] Fig. 2 is a cross-sectional view taken along line I1-I1' of the curved display device of Fig. 1. Fig. 3 is a cross-sectional view taken along line I2-I2' of the curved display device of Fig. 1. Fig. 4 is an enlarged view showing part FF1 in Fig. 2.

[0061] Referring to FIGS. 1 to 4, the first substrate (200) and the second substrate (300) may each include an insulating substrate made of glass, quartz, or the like, and structures such as wiring, metal, semiconductor layers, insulating films, color filters, and black matrices disposed thereon. The structures may be disposed on opposing surfaces (204, 304) of the insulating substrate of the first substrate (200) and the insulating substrate of the second substrate (300), respectively. One surface (204, 304) of the insulating substrate of the first substrate (200) and the insulating substrate of the second substrate (300) may be flat, but the opposite surface (or back surface) (201, 301) may include a protruding or recessed area due to etching or polishing. For convenience, the drawings omit the illustration of the structures disposed on the insulating substrates, and only the shapes of the insulating substrates of the first substrate (200) and the second substrate (300) are illustrated. Hereinafter, when referring to the shape of the back surface of the first substrate (200) or the second substrate (300), the shape may mean the shape of the back surface of the insulating substrate of the first substrate (200) or the shape of the back surface of the insulating substrate of the second substrate (300). However, the embodiment is not limited to the above example, and another additional layer may be disposed on the back surface of the insulating substrate of the first substrate (200) or the second substrate (300), and the layer may be etched or polished to include a protruding or recessed area.

[0062] The first substrate (200) and the second substrate (300) may each include a first thickness region having a first thickness and a second thickness region having a second thickness greater than the first thickness. The first thickness region may be, but is not limited to, a region whose thickness has been reduced by etching, and is hereinafter referred to as an etched region (220, 320). The second thickness region is a region protruding from the first thickness region, and is hereinafter referred to as a protruding region (211, 212, 311, 312).

[0063] A curved display device includes a display area located at the center and a non-display area (or bezel area) surrounding the display area. The etched area (220, 320) may be arranged to overlap the display area, and the protruding area (211, 212, 311, 312) may be arranged to overlap the non-display area. The etched area (220, 320) may extend to a part of the non-display area and further overlap the non-display area. On the other hand, the protruding area (211, 212, 311, 312) may not overlap the display area. The protruding area (211, 212, 311, 312) may be arranged at the edge of the curved display device. The etched area (220, 320) may be located inside the protruding area (211, 212, 311, 312).

[0064] To be more specific, the first substrate (200) may include first protruding regions (212, 211) formed at one end (right end in FIG. 2) and the other end (left end in FIG. 2) in the first direction (dr1), respectively. The second substrate (300) may include second protruding regions (312, 311) formed at one end and the other end in the first direction (dr), respectively. Here, the other end in the first direction (dr1) means the opposite direction of one end in the first direction (dr1), and is used with the same meaning when describing one end and the other end in the other direction hereinafter.

[0065] Each protruding region (211, 212, 311, 312) may be formed to protect the driving connection film (410) or prevent damage to the first substrate (200) or the second substrate (300) when the first substrate (200) or the second substrate (300) is bent into a desired curved shape while the thickness of the first substrate (200) or the second substrate (300) is reduced. However, the positions of the protruding regions (211, 212, 311, 312) are not limited to those illustrated. The protruding regions (211, 212, 311, 312) may be formed on the edge portion of the curved display device, that is, on the upper and lower sides (see FIG. 1) among the upper side, lower side, left side, and right side, or may be formed on the left and right sides, or may be formed only on the lower side, or may be formed on the entire upper, lower, left, and right sides (i.e., the entire edge portion of the curved display device). In some other embodiments, the protruding regions (211, 212, 311, 312) may be formed on only one of the first substrate (200) and the second substrate (300). The surface (back surface) (202, 203, 302, 303) of the protruding regions (211, 212, 311, 312) may include, but is not limited to, a polished surface.

[0066] In an exemplary embodiment in which the first substrate (200) protrudes in one direction (dr1) more than the second substrate (300) and the other side in the first direction (dr1) is aligned with each other, the width of the first protruding region (212) located on the one side in the first direction (dr1) may be larger than the width of the second protruding region (312), while the width of the first protruding region (211) located on the other side in the first direction (dr1) may be the same as the width of the second protruding region (311).

[0067] The first etching region (220) of the first substrate (200) may be located between the first protruding regions (212, 211), and the second etching region (320) of the second substrate (300) may be located in the second protruding regions (312, 311). The etching regions (220, 320) are recessed from the adjacent protruding regions (211, 212, 311, 312). The recessed surfaces of the etching regions (220, 320) become the back surfaces (201, 301) of the first substrate (200) and the second substrate (300), respectively.

[0068] The first etching region (220) and the second etching region (320) may completely overlap in the thickness direction. In addition, the width of the first etching region (220) in the first direction (dr1) and the width of the second etching region (320) in the first direction (dr1) may be the same. However, the present invention is not limited thereto.

[0069] The first etching region (220) and the second etching region (320) may have a uniform thickness. The thickness of the first etching region (220) and the thickness of the second etching region (320) may be the same, but are not limited thereto. The thickness of the first etching region (220) and the thickness of the second etching region (320) may be about 0.1 to about 0.8 times, or 0.4 to 0.6 times, the thickness of the protruding regions (211, 212, 311, 312), but are not limited thereto. In this way, since the first etching region (220) and the second etching region (320) have a thin thickness, the corresponding regions can be easily bent in a curved surface process.

[0070] The first substrate (200) and the second substrate (300) may include a connecting surface (230, 330) between each of the protruding regions (211, 212, 311, 312) and the etching region (220, 320). The inclined surface (230, 330) may be a right angle with respect to the back surface (201, 301) of the etching region (220, 320) or may be an inclined surface having an obtuse angle.

[0071] A liquid crystal layer (500) may be disposed between one side (204) of the first substrate (200) and one side (304) of the second substrate (300). In addition, a sealing member (110) is disposed between the first substrate (200) and the second substrate (300). The sealing member (110) is formed along the edge of the second substrate (300) between the first substrate (200) and the second substrate (300), and may be disposed to overlap the protruding areas (211, 212, 311, 312).

[0072] A first sealant (120) may be arranged on the outer surface of the sealing member (110). The first sealant (120) may be arranged to cover one side of the sealing member (110) located on one side of the first direction (dr1) in which the first substrate (200) is relatively protruded. The first sealant (120) may be arranged to contact one side (201, one side overlapping the first protruding area (212) as an upper surface of FIG. 2) of the protruding first substrate (200) and the side surface of the sealing member (110). The thickness of the first sealant (120) may be thicker than that of the sealing member (110). In one embodiment, the first sealant (120) may be positioned to contact one side (201) of the first substrate (200), the side of the sealing member (110), as well as part or all of one side (306) of the second substrate (300).

[0073] In one embodiment, the first sealant (120) may be formed of an acid-resistant material. For example, the first sealant (120) may include a silicone resin, an acrylic resin, an epoxy resin, a phenolic resin, a polyamide resin, a polyimide resin, an unsaturated polyester resin, a polyphenylene resin, a polyphenylenesulfides resin, or benzocyclobutene (BCB).

[0074] In some embodiments, the sealing member (110) may not be acid-resistant. In this case, the first sealing member (120) may be formed of an acid-resistant material, thereby preventing damage to the sealing member (110) from the etchant used in the etching process.

[0075] A drive connection film (410) is attached to one end of the first direction (dr1) of the first substrate (200). The drive connection film (410) serves to connect the first substrate (200) and the drive circuit board (420). The drive connection film (410) may be attached to one surface (201) of the first substrate (200) with a first conductive anisotropic film (431) interposed therebetween. However, the present invention is not limited thereto, and the drive connection film (410) may be directly attached to one surface of the first substrate (200) through soldering, ultrasonic bonding, or the like. The area where the drive connection film (410) is attached to the first substrate may be an area overlapping the first protruding area (212). The drive connection film (410) is a film including a signal line, and may be formed by including a flexible film. It may be a flexible printed circuit board (FPC), a tab (TAB), a connect film, or the like. The drive connection film (410) may be spaced apart from the first sealant (120). That is, the drive connection film (410) may be positioned on one side in the first direction (dr1) with respect to the first sealant (120).

[0076] A driving circuit board (420) may be attached to one end of the driving connection film (410). Attachment of the driving connection film (410) and the driving circuit board (420) may be achieved by a second conductive anisotropic film (432) interposed therebetween. If soldering or ultrasonic bonding is used to join the driving connection film (410) and the driving circuit board (420), the second conductive anisotropic film (432) may be omitted.

[0077] The driving circuit board (420) may be formed of a printed circuit board (PCB). The driving chip may be placed on the driving circuit board (420). In some embodiments, the driving chip may be placed on a driving connection film.

[0078] Although the drawing illustrates a case where the driving circuit board (420) and the driving connection film (410) connecting the driving circuit board (420) are arranged at one end of the first substrate (200) in the first direction (dr1), the driving circuit board (420) and the driving connection film (410) may be arranged at the other end of the first substrate (200) in the first direction (dr1), or may be arranged at one or the other end of the second direction (dr2). In addition, a plurality of driving circuit boards (420) and driving connection films (410) may be provided, and may be attached adjacent to two or more sides of the first substrate (200).

[0079] In some embodiments, a single drive circuit board (420) may be connected to the first substrate (200) by a plurality of drive connection films (410). That is, as illustrated in FIG. 1, a plurality of drive connection films (410) having a smaller width than a single drive circuit board (420) may be attached to the single drive circuit board (420). Adjacent drive connection films (410) may be spaced apart from each other.

[0080] A second sealant (130) may be placed on one end of the first direction (dr1) of the first substrate (200) and the second substrate (300). The second sealant (130) protects the sealing member (110) and the first sealant (120). That is, the second sealant (130) may play a role in preventing the first sealant (120), the sealing member (110), the liquid crystal layer (500), the connection area between the first substrate (200) and the drive connection film (410) from being damaged by the etchant during the etching process.

[0081] The second sealant (130) may be disposed on one edge of the curved display device where the drive connection film (410) is disposed. The second sealant (130) may be disposed along the long side of the curved display device. The length of the second direction (dr2) of the second sealant (130) may be substantially the same as the length of the long side of the curved display device. One end (side) of the second sealant (130) in the second direction may be aligned with one end (side) of the first substrate (200) and the second substrate (300), and the other end (side) of the second sealant (130) in the second direction may be aligned with one end (side) of the first substrate (200) and the second substrate (300), but is not limited thereto.

[0082] The second sealant (130) is in contact with one side surface (206) of the first substrate (200), and also in contact with one side surface (306) of the second substrate (300) or the outer surface of the first sealant (120) located on the outer side thereof, and may protrude in one direction (dr1). The second sealant (130) may be positioned to be spaced apart from the driving circuit board (420). That is, a space may be defined between the one side surface (135) of the second sealant (130) and the driving circuit board (420).

[0083] One side surface (135), which is one end surface in the first direction (dr1) of the second sealant (130), may be positioned between one end and the other end of the drive connection film (410). In the area where the drive connection film (410) is disposed, the second sealant (130) may surround one side (the upper side in FIG. 2), the other side (the lower side in FIG. 2) and the second direction (dr2) side surface of the drive connection film (410) and may be in direct contact with them. That is, in the cross-sectional view, the second sealant (130) may be divided with the drive connection film (410) therebetween. The second sealant (130) also surrounds and seals the area where the drive connection film (410) is connected to one side of the first substrate (200). In the space where the drive connection film (410) is surrounded by the second sealant (130), the drive connection film (410) may be fixed by the second sealant (130). The drive connection film (410) may include a fixed region fixed by the second sealant (130) and a non-fixed region located outside the end of the second sealant (130). The fixed region of the drive connection film (410) does not bend, but the non-fixed region may bend, so that the drive circuit board (420) attached to the drive connection film (410) may be folded toward the back surface (203, 201, 202) of the first substrate (200). In the space between adjacent drive connection films (410), the second sealant (130) may be integrally connected in the third direction (dr3), which is the thickness direction, without being divided.

[0084] One side (135) of the second sealant (130) can be flat in the third direction (dr3), regardless of whether one side (206) of the first substrate (200) protrudes more than one side (306) of the second substrate (300). That is, an end of the second sealant (130) located at a portion extending in one direction (dr1) of the first substrate (200) can be generally aligned with an end of the second sealant (130) located at a portion extending in one direction (dr1) of the second substrate (300).

[0085] The other side surface (133, 134) of the second sealant (130) may be arranged to be in contact with both one side surface (206) of the first substrate (200) and one side surface (306) of the second substrate (300) (or the outer surface of the first sealant (120). The second sealant (130) may also be arranged to be in contact with the protruding side surface (204) of the first substrate (200).

[0086] If the side of the second sealant (130) facing in the same direction as the back surface (301, 302, 303) of the second substrate (300) is defined as the first side (131) of the second sealant (130), and the side facing in the same direction as the back surface (201, 202, 203) of the first substrate (200) is defined as the second side (132) of the second sealant (130), the first side (131) and the second side (132) of the second sealant (130) can be parallel to each other. In addition, the first surface (131) of the second sealant (130) may be substantially at the same level as the back surface (303) of the second protruding area (312) of the adjacent second substrate (300), and the second surface (132) of the second sealant (130) may be substantially at the same level as the back surface (203) of the first protruding area (212) of the adjacent first substrate (200). That is, the first surface (131) of the second sealant (130) may be substantially located on the extended surface of the back surface (303) of the second protruding area (312), and the second surface (132) of the sealant (130) may be substantially located on the extended surface of the back surface (203) of the first protruding area (212). Here, being substantially at the same level or substantially positioned on an extension plane is used to mean not only being at the exact same level or positioned exactly on an extension plane, but also being positioned with an error of less than 5% of the overall thickness of the curved display device.

[0087] The first surface (131) and the second surface (132) of the second sealant (130) can be bent along the second direction (dr2) axis, similar to the second protruding area (312) of the second substrate (300) and the first protruding area (212) of the first substrate (200).

[0088] One side (135) of the second sealant (130) may form part of the edge of the curved display device. For convenience of explanation, the one side (135) of the second sealant (130) is sometimes referred to herein as the edge surface (135) of the second sealant (130). The edge surface (135) of the second sealant (130) may include, but is not limited to, a flat surface.

[0089] As illustrated in FIG. 4, the first surface (131) of the second sealant (130) may form a first angle (θ11) with the edge surface (135). The second surface (132) of the second sealant (130) may form a second angle (θ21) with the edge surface (135). The first angle (θ11) and the second angle (θ21) may be the same, but are not limited thereto. For example, the first angle (θ11) and the second angle (θ21) may be right angles. That is, the second sealant (130) may include a corner edge formed by the first surface (131) and the edge surface (135) and the second surface (132) and the edge surface (135).

[0090] The second sealant (130) may form a third angle (θ12) with one surface of the driving connection film (410) and a fourth angle (θ22) with the other surface of the driving connection film (410). The sum of the third angle (θ12) and the fourth angle (θ22) may be 180°. In addition, the third angle (θ12) and the fourth angle (θ22) may each be equal to 90°.

[0091] The second sealant (130) may include an acid-resistant resin. For example, the second sealant (130) may include a silicone-based resin, an acrylic resin, an epoxy resin, a phenolic resin, a polyamide-based resin, a polyimide-based resin, an unsaturated polyester-based resin, a polyphenylene-based resin, a polyphenylenesulfides-based resin, or benzocyclobutene (BCB). In some embodiments, the second sealant (130) may be formed of the same material as the first sealant (120).

[0092] As described above, in the case of the curved display device according to the present embodiment, since the second sealant (130) surrounds a portion of the driving connection film (410), the driving connection film (410) can be strongly fixed, thereby improving ease of processing. In addition, since the first surface (131) and the second surface (132) of the second sealant (130) are formed to have substantially the same height as the respective back surfaces (202, 203, 302, 303) of the respective protruding regions (211, 212, 311, 312) of the first substrate (200) and the second substrate (300), respectively, processing precision can be improved. In addition, by minimizing the occurrence of a gap between the first substrate (200), the second substrate (300), and the second sealant (130), penetration of the etchant can be suppressed during the etching process, and resulting breakage defects can be prevented.

[0093] The curved display device may include a protrusion positioned along at least one side of the first substrate (200). The protrusion may correspond, for example, to the protrusion areas (212, 312) of FIG. 3. The protrusion may include a border portion (511) and a protrusion pattern (513) protruding from the border portion (511). The curved display device may include a slimming portion (515, 517) surrounded by the border portion (511). For example, the slimming portion may correspond to an etching area (220 of FIG. 3).

[0094] A release film (240) including one or more protruding patterns may be attached to a portion of a first substrate (200). The release film (240) may be disposed to overlap a protruding region (212) of the first substrate. The release film (240) may be disposed to overlap all or part of the protruding region (212). Depending on the embodiment, the release film (240) may also be formed to extend into the etching region (220).

[0095] One side of the release film (240) may be formed on a portion of the first substrate (200). The thickness of the portion from which the release film is removed may be the same as or different from the etched area (220).

[0096] The first substrate (200) may include a TFT region. A tab may be connected to the upper end of the TFT region. The tab, the protruding pattern, and the sealant (the first sealant (120) or the second sealant (130)) may overlap in the thickness direction of the curved display device.

[0097] A curved display device according to one embodiment can be designed to protect circuit components on a driving connection film from an etchant during a process of slimming a display panel, and at the same time, to form a slimming area that is not slimmed or is slimmed to a lower degree than a slimming area by arranging a masking member, thereby reducing bending stress of the display device.

[0098] For example, a curved display device includes a protrusion part including a border part (511) and a protrusion pattern (513) as described above, and a second slimming part (517) is arranged between adjacent protrusion patterns (513), thereby protecting circuit components on a driving connection film from an etchant during the slimming process of the display panel, and reducing bending stress of the display device.

[0099] The protruding pattern (513) can extend parallel to the extension direction of the curvature center axis of the curved display device.

[0100] Fig. 5 is a drawing for explaining the structure of a heteromorphic film including a plurality of protruding patterns.

[0101] Referring to FIG. 5, a substrate (e.g., the first substrate (200) of FIGS. 2 to 4) constituting a curved display device may include a border portion (511) and slimming portions (515, 517). The border portion (511) may be arranged along at least one side of the substrate. The slimming portions (515, 517) may have a shape surrounded by the border portion (511).

[0102] The border portion (511) may be physically connected to a plurality of protruding patterns (513) formed on one surface of the slimming portion (515, 517). The slimming portion may include a first slimming portion (515) and a second slimming portion (517). A portion of the slimming portion (e.g., the second slimming portion (517)) may be positioned between the plurality of protruding patterns (513).

[0103] The thickness of the substrate in the slimming section (515, 517) may be thinner than the thickness of the substrate in the plurality of protruding patterns (513). The thickness of the substrate in the first slimming section (515) and the thickness of the substrate in the second slimming section (517) may be the same, but the embodiments of the present specification are not limited thereto.

[0104] The first slimming portion (515) may be positioned on the display area of ​​the curved display device. The second slimming portion (517) may be positioned between a plurality of protruding patterns (513). The first slimming portion (515) and the second slimming portion (517) may be physically connected.

[0105] Although FIG. 5 shows that the thickness of the first slimming portion (515) and the step of the second slimming portion (517) do not exist because the heteromorphic film is removed, depending on the embodiment, a structure in which a step exists between the first slimming portion (515) and the second slimming portion (517) is also possible.

[0106] The plurality of protruding patterns (513) may be circular or polygonal patterns. In the example of FIG. 5, the protruding patterns (513) have a rectangular shape, but depending on the embodiment, they may have a circular or arbitrary polygonal shape.

[0107] Each of the plurality of protruding patterns (513) may include a first side (519) and at least two second sides (521). The first side (519) may be parallel to one side of the substrate (e.g., the long side (523) of the substrate). The first side (519) may be positioned to protrude in the direction of the display area of ​​the curved display device. The second side (521) may form a specific angle with the first side (519).

[0108] The first side (519) and the second side (521) may be perpendicular. When the first side (519) and the second side (521) are perpendicular, the second side (521) may be parallel to another side of the substrate (e.g., the short side (525) of the substrate). Depending on the embodiment, the long side (523) and the short side (525) of the substrate may be swapped.

[0109] The width of the protruding pattern (513) measured in the direction in which the first side (519) extends (e.g., the second direction (dr2) of FIG. 5) may be the first length, and the spacing between the protruding patterns (513) (e.g., the spacing between the protruding patterns (513) measured in the second direction (dr2) of FIG. 5) may be the second length. The spacing between the protruding patterns (513) may be the width of the second slimming portion (517). According to one embodiment, the first length may decrease and the second length may increase toward the end of the protruding pattern (513).

[0110] In another embodiment, the combined pitch of the first length and the second length may be constant. In another embodiment, the first length and the second length may be different. In another embodiment, the first length may increase and the second length may decrease toward the end of the protruding pattern (513).

[0111]

[0112] *One side of the substrate can correspond to a side that is curved at a preset curvature. A plurality of protruding patterns (513) can be formed only in the upper area of ​​the TFT substrate of the display device.

[0113] The protruding pattern (513) may have a heteromorphic pattern (or, comb pattern).

[0114] As described above, the length of the protrusion (the length in the first direction (dr1) of FIG. 5) is related to the area of ​​the masking member arranged to protect the driving connection film (see 410 of FIG. 4) in the process of slimming the display panel (the process of forming the first slimming portion (515)). The masking member covers the protrusion, and the overlapping area of ​​the masking member and the display panel may be equal to the length (or area) of the protrusion formed after the process, but the embodiments of the present specification are not limited thereto.

[0115] During the slimming process of the display panel, the etchant may not only affect the display panel, but may also partially flow and penetrate the drive connection film (see 410 in FIG. 4). To prevent the etchant from penetrating the drive connection film (410), a masking member may be arranged to cover the inside of the display panel. However, in this case, the area of ​​the protrusion formed after the slimming process may increase. As described above, if the area of ​​the protrusion is large, the bending stress may increase during the bending process of the flat panel display device, which may cause physical damage to the display device.

[0116] Accordingly, the present specification proposes a structure in which a protruding pattern (513) and a second slimming portion (517) are alternately and repeatedly arranged along a second direction (dr2) to reduce bending stress while securing a sufficient area for the arrangement of a masking member to prevent penetration of an etchant into a drive connection film (410).

[0117]

[0118] Figures 6 to 9 show examples of protrusion patterns.

[0119] Referring to FIGS. 6 to 9, when the protruding pattern (e.g., the protruding pattern (513) of FIG. 5) is a polygon (e.g., a rectangle or a trapezoid), the shape of the protruding pattern can be defined by a first width (610), a second width (630), a pitch (650), a first width (670), and a second width (690).

[0120] The first width (610) may correspond to the second length of FIG. 5, and the second width (630) may correspond to the first length of FIG. 5.

[0121] Figures 7 to 9 illustrate examples of protrusion patterns according to various embodiments.

[0122] Referring to FIGS. 7 and 8, the first width (610) may be smaller than the second width (630). For example, as illustrated in FIG. 7, the second width (630) may be about 1.5 times the first width (610). For another example, as illustrated in FIG. 8, the second width (630) may be about 1.8 times the first width (610). Referring to FIG. 9, the protruding pattern (513) and the second slimming portion (517) may have a trapezoidal shape. A corner portion located at an end of the protruding pattern (513) and / or a corner portion located at an end of the second slimming portion (517) may be rounded with a radius of curvature (R1). The second width (630) may be about 1.5 times the first width (610), but is not limited thereto.

[0123] Hereinafter, a manufacturing method according to one embodiment of the above-described display device will be described.

[0124]

[0125] Fig. 10 shows a schematic flowchart of a method for manufacturing a curved display device according to one embodiment.

[0126] Referring to FIG. 10, a method for manufacturing a curved display device according to one embodiment may include a step (1010) of preparing a flat display device including a substrate member having a sealing member formed thereon, a step (1030) of attaching a release film to one surface of the substrate member, a step (1050) of floating a plurality of protruding patterns on the release film, and a step (1070) of removing a portion of the release film.

[0127] The floating step (1050) may include floating a plurality of protruding patterns along one side of the substrate member from one end of the substrate member to another end of the substrate member.

[0128] The floating step (1050) may include a step of floating a first side that is parallel to one side of the substrate member and protrudes toward a display area of ​​the display device, and a step of floating a second side that forms a specific angle with the first side. The step of floating a protruding pattern (1050) may be performed by a laser.

[0129] The removing step (1070) may include removing another portion of the release film closer to the center of the substrate member to leave a portion of the release film attached to the edge of the substrate member.

[0130] Based on the protruding pattern engraved by the laser, a protruding pattern can be formed on the substrate by removing the release film. By forming the protruding pattern on the substrate, the TFT area breakage defect that occurs during the bending process of the flat panel display device can be improved.

[0131]

[0132] Although embodiments of the present invention have been described with reference to the attached drawings, those skilled in the art will appreciate that the present invention can be implemented in other specific forms without altering the technical spirit or essential characteristics of the present invention. Therefore, the embodiments described above should be understood to be illustrative in all respects and not restrictive.

Claims

1. Including a curved substrate having an arbitrary curvature, The above substrate is, a protrusion arranged along at least one edge of the substrate; and including a slimming portion extending from the above protrusion, The above protrusion is, A border portion, and a plurality of protruding patterns protruding from the border portion, A portion of the slimming portion is placed between the plurality of protruding patterns. Curved display device.

2. In paragraph 1, A curved display device in which the thickness of the substrate in the slimming section is thinner than the thickness of the substrate in the plurality of protruding patterns.

3. In paragraph 1, The above slimming part is, A first slimming portion arranged on the display area of ​​the curved display device; and A plurality of second slimming portions arranged in a non-display area of ​​the curved display device and connected to the first slimming portion, and arranged between the plurality of protruding patterns, Curved display device.

4. In paragraph 3, The thickness of the substrate in the first slimming section and the thickness of the substrate in the second slimming section are the same. Curved display device.

5. In paragraph 1, The above multiple protruding patterns are, A circular or polygonal pattern, Curved display device.

6. In paragraph 1, Each of the above plurality of protruding patterns is A first side that is parallel to one side of the substrate and protrudes in the direction of the display area of ​​the curved display device; and Including two second sides forming a specific angle with the first side, Curved display device.

7. In paragraph 6, The first side and the second side are perpendicular, Curved display device.

8. In paragraph 6, The width of the above protruding pattern is the first length, The spacing between the above protruding patterns is a second length, As the end of the above protrusion pattern approaches, the first length decreases and the second length increases. Curved display device.

9. In paragraph 6, The width of the above protruding pattern is the first length, The spacing between the above protruding patterns is a second length, The pitch, which is the sum of the first length and the second length, is constant. Curved display device.

10. In paragraph 9, The first length and the second length are different, Curved display device.

11. In paragraph 6, The above side of the above substrate corresponds to a side curved with the preset curvature, Curved display device.

12. In paragraph 7, The above multiple protruding patterns are, Formed only in the upper area of ​​the TFT substrate of the above display device, Curved display device.

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