Display device and method of manufacturing the same

A display device and a method of manufacturing the same are provided. A display device includes: a display panel including a first area, a second area, and a bending area between the first area and the second area; a first polarizing film on a first surface of the first area of the display panel; and a second polarizing film on a first surface of the second area of the display panel, and the first and second polarizing films are spaced apart from each other with the bending area therebetween.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of Korean Patent Application No. 10-2018-0094324, filed on Aug. 13, 2018 in the Korean Intellectual Property Office, the entire disclosure of which is incorporated herein by reference.

BACKGROUND

Aspects of embodiments of the present disclosure relate to a display device and a method of manufacturing the same.

2. Description of the Related Art

A flexible display device can be used not only in portable electronic devices, such as a mobile phone, a smartphone, a tablet personal computer (PC), a smart watch, a watch phone, a mobile communication terminal, an electronic notebook, an electronic book, a portable multimedia player (PMP), a navigation device, or an ultra-mobile PC (UMPC), but also in various other products, such as a television (TV), a notebook computer, a monitor, a billboard, or an Internet-of-Things (IoT) device.

A flexible display device, which is a display device having a display unit and a driving unit formed on a flexible substrate, including a flexible material, so as to be able to display an image even when bent like paper, has attracted attention as a next-generation display device. The flexible display device may be bent to have a predetermined thickness in a thickness direction. However, as the predetermined thickness increases, the dead space of the flexible display device increases. Thus, research has been conducted on ways to reduce the predetermined thickness.

SUMMARY

According to an aspect of exemplary embodiments of the present disclosure, a slim display device is provided.

According to an aspect of exemplary embodiments of the present disclosure, a method of manufacturing a slim display device with an improved process efficiency is provided.

According to one or more exemplary embodiments of the present disclosure, a display device includes: a display panel including a first area, a second area, and a bending area between the first area and the second area; a first polarizing film on a first surface of the first area of the display panel; and a second polarizing film on a first surface of the second area of the display panel, wherein the first and second polarizing films are spaced apart from each other with the bending area therebetween.

In an exemplary embodiment, the first and second areas of the display panel overlap with each other in a thickness direction, and second surfaces of the first and second areas of the display panel are opposite to each other.

In an exemplary embodiment, the second polarizing film overlaps with the first polarizing film in the thickness direction.

In an exemplary embodiment, the first and second polarizing films include a same material.

In an exemplary embodiment, a thickness of the first polarizing film is the same as a thickness of the second polarizing film.

In an exemplary embodiment, a display device may further include an adhesive member between the second surfaces of the first and second areas of the display panel and bonding the second surfaces of the first and second areas of the display panel.

In an exemplary embodiment, a display device may further include a gap between a first side of the adhesive member and a second surface of the bending area of the display panel; and a spacer in the gap, wherein the spacer is in contact with the first side of the adhesive member and the second surface of the bending area of the display panel.

In an exemplary embodiment, a display device may further include a passivation film on a first surface of the bending area of the display panel.

In an exemplary embodiment, a first side of the passivation film faces a first side of the first polarizing film, and a second side of the passivation film faces a first side of the second polarizing film.

In an exemplary embodiment, the passivation film covers a part of a top surface of the first polarizing film or a part of a top surface of the second polarizing film.

In an exemplary embodiment, a direction in which a first side of the first polarizing film extends is the same as a direction in which a first side of the second polarizing film extends, and the first sides of the first and second polarizing films face each other.

In an exemplary embodiment, a distance between the first sides of the first and second polarizing films is uniform along the direction in which the first side of the first polarizing film extends.

In an exemplary embodiment, a display device may further include a driver chip on the first surface of the second area of the display panel, wherein the second polarizing film is between the bending area and the driver chip.

In an exemplary embodiment, the second polarizing film covers a first side and a top surface of the driver chip.

In an exemplary embodiment, the second area of the display panel includes a sub-area adjacent to the bending area and a driver chip area adjacent to an end of the second area, and the second polarizing film is located in the sub-area and the driver chip area and in a part of the driver chip area between a second surface of the display panel and the driver chip.

In an exemplary embodiment, the first and second polarizing films include burr-shaped portions near the bending area.

In an exemplary embodiment, the display panel includes recessed scratches near the bending area in the thickness direction.

In an exemplary embodiment, the display panel includes soot on the first surface of the bending area of the display panel.

According to one or more embodiments of the present disclosure, a method of manufacturing a display device includes: arranging a polarizing film on a first surface of a display panel including a first area, a second area, and a bending area between the first area and the second area; and separating the polarizing film into a first polarizing film, which is on the first area of the display panel, and a second polarizing film, which is on the second area of the display panel, by removing the polarizing film from the bending area of the display panel and from an area on a side of the second area of the display panel.

In an exemplary embodiment, the method of manufacturing a display device further includes arranging a passivation film on the bending area of the display panel, and arranging a driver chip in an area where the second area of the display panel is exposed.

According to an aspect of the aforementioned and other exemplary embodiments of the present disclosure, a slim display device may be provided.

According to another aspect, a method of manufacturing a slim display device with an improved process efficiency may be provided.

Other features and exemplary embodiments may be apparent from the following detailed description, the drawings, and the claims.

DETAILED DESCRIPTION

Aspects and features of the present invention and methods for achieving the aspects and features will be apparent by referring to some exemplary embodiments to be described in further detail with reference to the accompanying drawings. However, the invention is not limited to the embodiments disclosed herein, but may be implemented in various forms. The matters defined in the description, such as the detailed construction and elements, are merely provided to assist those of ordinary skill in the art in a comprehensive understanding of the invention and are not limiting of the invention, which is set forth within the spirit and scope of the appended claims.

Where an element is described as being related to another element, such as being “on” another element or “located on” a different element or a layer, this includes both a case in which an element is located directly on another element or a layer and a case in which an element is located on another element via one or more other layers or one or more other elements. In contrast, where an element is described as being is related to another element such as being “directly on” another element or “located directly on” a different element or a layer, this indicates a case in which an element is located on another element or a layer with no intervening element or layer therebetween.

Throughout the specification, the same reference numerals are used for the same or similar parts.

FIG. 1is a perspective view of a display device according to an exemplary embodiment of the present disclosure;FIG. 2is a layout view of the display device ofFIG. 1;FIG. 3is a cross-sectional view, taken along the line III-III′ ofFIG. 2, of the display device ofFIG. 1; andFIG. 4is a cross-sectional view illustrating the display device ofFIG. 3in a bent state.

Referring toFIGS. 1 through 4, a display device1may include a display module200, which displays an image, and a panel bottom structure100, which is disposed below the display module200. As illustrated inFIG. 1, the display module200may be bent to surround a side of the panel bottom structure100from the outside.

Although not specifically illustrated, the display device1may include a window disposed above the display module200. The window protects the display module200and transmits light emitted from the display module200therethrough. The window may overlap with the display module200and may be disposed to cover the entire surface of the display module200. The window may be formed of glass or the like.

In an embodiment, the display device1may further include a touch member disposed between the window and the display module200. For example, the touch member may have substantially the same size as the display module200and may be disposed to overlap with the display module200, and the sides of the touch member may be aligned with the sides of the display module200. However, the present disclosure is not limited to this example. The touch member may be of a rigid panel type or of a flexible panel or film type.

The display module200and the touch member, and the touch member and the window, may be bonded together via transparent bonding layers (not illustrated), such as an optically clear adhesive (OCA) or an optically clear resin (OCR). In an embodiment, the touch member may not be provided, in which case, the display module200and the window may be bonded together via the transparent bonding layer. In some exemplary embodiments, the display module200may include a touch electrode unit therein.

The display module200may include a display panel210, which displays an image, a polarizing film230, which is disposed on a part of a first surface of the display panel210, and a passivation film240, which is disposed on a part of the first surface of the display panel210, exposed by the polarizing film230.

The display panel210may be an organic light-emitting diode (OLED) panel, a liquid crystal display (LCD) panel, a field emission display (FED) panel, or an electrophoretic display panel, for example. In the description that follows, it is assumed that an OLED display panel is used as the display panel210.

As illustrated inFIG. 2, the display panel210may include a display area DA in which an image is displayed and a non-display area NDA which is disposed at the periphery of the display area DA. In an embodiment, in a plan view, the display device1may have a rectangular shape with right-angled or rounded edges. However, the shape of the display area DA is not particularly limited, and the display area DA may have a circular shape, an elliptical shape, or any of various other shapes. The non-display area NDA may be disposed at the periphery of the display area DA. In a case in which, in a plan view, the display area DA has a rectangular shape with right-angled or rounded edges, the display area DA includes two long sides and two short sides, and the non-display area NDA may be disposed adjacent to at least one side of the display area DA.FIGS. 1 through 4illustrate an example in which the non-display area NDA is disposed adjacent to both long sides and both short sides of the display area DA.

In an exemplary embodiment, the display area DA and parts of the non-display area NDA may form a main area MA. The main area MA may include the entire display area DA and parts of the non-display area NDA adjacent to both long sides and the upper short side, in a second direction DR2, of the display area DA. As illustrated inFIG. 3, the main area MA may be generally flat.

Another part of the non-display area NDA may form a bending area BA. The bending area BA may be disposed on at least one side of the main area MA.FIGS. 1 through 4illustrate an example in which a single bending area BA is disposed adjacent to the lower side of the main area MA, but the bending area BA may also be disposed adjacent to the other sides of the main area MA, i.e., the left, right, and upper sides of the main area MA. The bending area BA may also be disposed on two or more sides of the main area MA. The bending area BA may be bent in a direction opposite to a display direction, e.g., in a downward direction in a case in which the display device1is of a top emission type (i.e., in a direction toward below the main area MA).

Another part of the non-display area NDA may form a sub-area SA. The sub-area SA is disposed to extend from the bending area BA. The sub-area SA may be parallel to the main area MA when the display panel210is bent. The sub-area SA may overlap with the main area MA in a thickness direction. In an exemplary embodiment, the entire sub-area SA may overlap with the main area MA in the thickness direction.

The display panel210may include a base substrate211, a driving layer212, an organic light-emitting element layer213, and an encapsulation layer214. The base substrate211may be disposed in and across the main area MA, the bending area BA, and the sub-area SA. The base substrate211may be a flexible substrate including a flexible material, such as polyimide.

In an embodiment, the driving layer212may be disposed on the entire surface of the base substrate211. The driving layer212may include elements for providing signals to the organic light-emitting element layer213. The driving layer212may include various signal lines, for example, scan lines (not illustrated), data lines (not illustrated), power lines (not illustrated), and emission lines (not illustrated). The driving layer212may include transistors and capacitors. The transistors include a switching transistor (not illustrated) and a driving transistor (not illustrated), which are provided in each pixel (not illustrated).

The organic light-emitting element layer213may be disposed on the first surface of the main area MA of the display panel210. The organic light-emitting element layer213may include an organic light-emitting diode (not illustrated). For example, a front emission-type organic light-emitting diode may be provided and may emit light through a display surface. The organic light-emitting diode may include an anode electrode (not illustrated), an organic layer (not illustrated) and a cathode electrode (not illustrated). The cathode electrode may be a common electrode, but the present disclosure is not limited thereto.

The organic light-emitting element layer213may be sealed by the encapsulation layer214. The encapsulation layer214may seal the organic light-emitting element layer213and may thus prevent or substantially prevent external air and/or moisture from penetrating the organic light-emitting element layer213. The encapsulation layer214may be formed as a single- or multilayer inorganic film or as a layer in which an inorganic film and an organic film are alternately stacked.

The polarizing film230may be disposed on the first surface of the display panel210. The polarizing film230may be attached to the display panel210via a first adhesive member220, which is disposed between the polarizing film230and the display panel210. In an embodiment, the polarizing film230may be disposed in the main area MA and the sub-area SA of the display panel210, but not in the bending area BA of the display panel210, and may thus expose a part of the first surface of the bending area BA of the display panel210. The passivation film240may be further disposed on the part of the first surface of the bending area BA, exposed by the polarizing film230. The polarizing film230may further expose a part of the sub-area SA that is distant from the bending area BA. Pad terminals (not illustrated) may be disposed on the part of the first surface of the sub-area SA, exposed by the polarizing film230, and a data driver integrated circuit250may be connected to the pad terminals with an anisotropic conductive film (ACF) disposed between the pad terminals.

The panel bottom structure100may be disposed on a second surface of the display module200. In an embodiment, the panel bottom structure100may overlap with the main area MA and the sub-area SA of the display panel210and may also overlap with a part of the bending area BA that is adjacent to the main area MA. The panel bottom structure100may be disposed to face, and be parallel to, the main area MA and the sub-area SA, which faces the main area MA in the thickness direction when the display panel210is bent. The panel bottom structure100may include a second adhesive member110and a lower sheet120.

When the display device1is bent, the second adhesive member110may partially overlap with the main area MA and the sub-area SA and may extend beyond the main area MA and the sub-area SA to partially overlap with the bending area BA. The second adhesive member110may bond the main area MA and the sub-area SA, which overlaps with the main area MA in the thickness direction when the display panel210is bent. In an embodiment, the second adhesive member110may include a buffer material and may thus absorb external and/or internal shock applied to parts of the display panel210that are bonded together in the thickness direction. In an embodiment, the second adhesive member110may include a foam material. Also, where the second adhesive member110further extends to overlap with the bending area BA, the second adhesive member110may fix the bent state of the display panel210, but the present disclosure is not limited thereto. Alternatively, the second adhesive member110may be disposed to overlap only with the main area MA and the sub-area SA, but not with the bending area BA.

The display device1may have a gap between the display panel210bent in the bending area BA and the first adhesive member110. In one or more exemplary embodiments, a spacer member (130ofFIG. 21) may be provided in the gap.

In an exemplary embodiment, the type of the second adhesive member110is not particularly limited as long as the second adhesive member110has an adhesive function. For example, the second adhesive member110may be a double-sided tape. In an embodiment, the second adhesive member110may include a tape substrate111, a first adhesive layer112disposed between a first surface of the tape substrate111and the second surface of the display panel210, and a second adhesive layer113disposed between a second surface of the tape substrate111and the second surface of the display panel210.

In an embodiment, the tape substrate111may be formed of polyethylene terephthalate (PET), polyimide (PI), polycarbonate (PC), polyethylene (PE), polypropylene (PP), polysulfone (PSF), polymethyl methacrylate (PMMA), triacetyl cellulose (TAC), a cyclo-olefin polymer (COP), or the like. The first and second adhesive layers112and113may be adhesive layers or resin layers. For example, the first and second adhesive layers112and113may contain a polymer material, such as a silicone-based polymer, a urethane-based polymer, a silicone-urethane hybrid polymer, an acrylic polymer, an isocyanate polymer, a polyvinyl alcohol polymer, a gelatin polymer, a vinyl polymer, a latex polymer, a polyester polymer, or a water-based polyester polymer.

The lower sheet120may be disposed adjacent to the second adhesive member110in the second direction DR2, may overlap with the second surface of the main area MA of the display panel210in the thickness direction, and may partially overlap with the second surface of the sub-area SA of the display panel210. The lower sheet120may include at least one functional layer. The functional layer may be a layer that performs a heat dissipation function, an electromagnetic wave shielding function, a grounding function, a buffering function, an intensity enhancement function, a support function, and/or a digitizing function, for example. The functional layer may be a sheet layer, a film layer, a thin layer, a coating layer, a panel, a plate, or the like. One functional layer may be formed as a single-layer film, but may also be formed as a stack of a plurality of thin films or coating layers. The functional layer may be, for example, a supporting substrate, a heat dissipation layer, an electromagnetic wave shielding layer, a shock absorbing layer, or a digitizer.

As described above, the polarizing film230may be disposed on the first surface of the display panel210. The polarizing film230may be attached to the display panel210via the first adhesive member220, which is disposed between the polarizing film230and the display panel210. The first adhesive member220may be a transparent bonding layer such as an OCA or an OCR, but the present disclosure is not limited thereto. Alternatively, the first adhesive member220, like the second adhesive member110, may be formed as a double-sided tape. In an embodiment, the polarizing film230may include a first polarizing film231and a second polarizing film232, which is spaced apart from the first polarizing film231.

The polarizing film230may be disposed in the main area MA and the sub-area SA of the display panel210, but not in the bending area BA of the display panel210, to expose the first surface of the bending area BA. Although not specifically illustrated, a light phase retardation film may be further disposed on a first surface or a second surface of the polarizing film230. The light phase retardation film may be a quarter-wave plate. In an embodiment, the light phase retardation film may be disposed on a first surface of the first polarizing film231, but not on a first surface of the second polarizing film232.

The polarizing film230may prevent or substantially prevent the reflection of external light by selectively transmitting therethrough, and/or absorbing, light incident from the outside of the display device1. In an exemplary embodiment, the polarizing film230may be an absorptive polarizing film. The polarizing film230may include a flexible material, such as polyvinyl alcohol (PVA). The polarizing film230may have an absorption axis in one direction. The polarizing film230may have an absorptive polarization characteristic for polarization components vibrating in a direction parallel to its absorption axis. The term “absorptive polarization characteristic,” as used herein, refers to the characteristic of imparting a polarization property to light by allowing the transmission of polarization components vibrating in a direction parallel to a transmission axis and partially absorbing polarization components vibrating in a direction that crosses the transmission axis. That is, the polarizing film230may have an absorptive polarization characteristic for polarization components vibrating in the direction parallel to its absorption axis and may thus absorb polarization components vibrating in the direction parallel to its absorption axis, as illustrated inFIG. 4, but the present disclosure is not limited thereto. The polarizing film230may be a reflective polarizing film selectively transmitting therethrough, and/or reflecting, polarization components of external light.

The first polarizing film231may be disposed on the first surface of the display panel210to overlap with the main area MA in the thickness direction, but the present disclosure is not limited thereto. In an embodiment, the first polarization film231may extend over to the bending area BA and may overlap with the bending area BA in the thickness direction. The second polarizing film232may be disposed on the first surface of the display panel210to overlap with the sub-area SA in the thickness direction, but the present disclosure is not limited thereto. In an embodiment, the second polarization film232may extend over to the bending area BA and may overlap with the bending area BA in the thickness direction. The first and second polarizing films231and232may face each other.

The first polarizing film231not only can prevent or substantially prevent the reflection of external light by selectively transmitting therethrough, and/or absorbing, light incident from the outside of the display device1, but also may maintain the flatness of the display panel210by being disposed on the first surface of the main area MA of the display panel210to support the display panel210. On the other hand, the second polarizing film232, unlike the first polarizing film231, may not prevent the reflection of external light. However, the second polarizing film232may be formed of the same film as the first polarizing film231and may maintain the flatness of the display panel210, like the first polarizing film231, by being disposed in the sub-area SA of the display panel210.

The first adhesive member220includes the first adhesive film221, which is disposed between, and bonds together, the first surface of the main area MA of the display panel210and a second surface of the first polarizing film231, and the second adhesive film222, which is disposed between, and bonds together, the first surface of the sub-area SA of the display panel210and a second surface of the second polarizing film232. In the main area MA, the second surface of the first polarizing film231may be attached to the first surface of the display panel210via the first adhesive film221, and in the sub-area SA, the second surface of the second polarizing film232may be attached to the first surface of the display panel210via the second adhesive film222. In an embodiment, the first and second polarizing films231and232may be disposed in a same layer and may include a same material.

In an exemplary embodiment, the passivation film240may be further disposed in the bending area BA, particularly, on the part of the first surface of the display panel210exposed by the polarizing film230. The passivation film240may be disposed on the first surface of the bending area BA of the display panel210. The passivation film240may be bent to surround, from the outside, the first surface of the bending area BA of the display panel210. One side of the passivation film240may be adjacent to sides of the first polarizing film231and the first adhesive film221, and the other side of the passivation film240may be adjacent to sides of the second polarizing film232and the second adhesive film222. However, the present disclosure is not limited to this. Alternatively, both sides of the passivation film240may not be in contact with the sides of the first and second polarizing films231and232and the sides of the first and second adhesive films221and222.

When the display panel210including the base substrate211is bent, the passivation film240may be disposed on the first surface of the display panel210to reinforce the strength of the display panel210, to alleviate stress of the bending area BA, and, thus, to prevent or substantially prevent damage to the display device1. For example, the passivation film240may include an acrylic resin or a silicone-based resin and may further include polymer-based fine particles, such as rubber including silica, epoxy, an epoxy hybrid, or the like. The passivation layer240may be formed by a coating method, but the present disclosure is not limited thereto. Alternatively, the passivation film240may be formed by attaching a single film or a stack of films including PET. In one or more exemplary embodiments, the passivation film240may cover the sides of the first and second polarizing films231and232and/or the first surfaces of the first and second polarizing films231and232.

The data driver integrated circuit250may be connected to the pad terminals on the part of the sub-area SA that is distant from the bending area BA and exposed by the polarizing film230. In an exemplary embodiment, a data driver chip may be used as the data driver integrated circuit250. In an embodiment, the data driver chip250may be mounted directly on a flexible substrate in a chip-on-plastic (COP) manner. As illustrated inFIG. 4, the data driver chip250may be disposed adjacent to the second polarizing film232and the second adhesive film222and may be placed in contact with the sides of the second polarizing film232and the second adhesive film222. However, in one or more exemplary embodiments, the data driver chip250may have a first surface and sides covered by the polarizing film230, particularly, the second polarizing film232, and may have a second surface placed in contact with the first surface of the second polarizing film232. In an embodiment, the data driver chip250may be attached to the first surface of the display panel210via a flexible film in a chip-on-film (COF) manner.

As described above, the display panel210may include generally flat areas, i.e., the main area MA and the sub-area SA, and a non-flat area disposed between the main area MA and the sub-area SA, i.e., the bending area BA. In order to maintain the flatness of the flat areas of the display panel210, a supporting structure may be disposed on first or second surfaces of the flat areas of the display panel210, i.e., the first or second surfaces of the main area MA and the sub-area SA. However, if the supporting structure is disposed on the first surface of the display panel210, the transmission of light emitted from the display panel210may be interfered with, and as a result, the emission efficiency of the display device1may be lowered. On the other hand, if the supporting structure is disposed on the second surface of the display panel210, the total thickness of the display device1may increase due to the thickness of the supporting structure, and, as a result, dead space may increase in the display device1. Accordingly, the emission efficiency of the display device1may also be lowered.

According to the display device1, the polarizing film230is disposed on the first surface of the main area MA and the sub-area SA and may thus support the flat areas of the display panel210. In this case, the general thickness and dead space of the display device1may be considerably reduced. In addition, a process for forming a separate structure on the second surface of the display panel210may be omitted, and, as a result, process efficiency may be improved.

Other exemplary embodiments of the present disclosure will hereinafter be described. In the previous and subsequent exemplary embodiments, like reference numerals indicate like elements, and, thus, descriptions thereof may be omitted or simplified.

FIG. 5is a cross-sectional view of a display device according to another exemplary embodiment of the present disclosure; andFIG. 6is a cross-sectional view illustrating the display device ofFIG. 5in a bent state.

Referring toFIGS. 5 and 6, a display device2differs from the display device1ofFIGS. 1 through 4in that a passivation film240_1of a display module200_1extends over to, and covers, not only the adjacent sides of first and second polarizing films231and232, but also parts of the first surfaces of the first and second polarizing films231and232.

The passivation film240_1may cover the side of the first polarizing film231that is aligned with the boundary between a bending area BA and a main area MA and a part of the first surface of the first polarizing film231. Also, the passivation film240_1may cover the side of the second polarizing film232that is aligned with the boundary between the bending area BA and a sub-area SA and a part of the first surface of the second polarizing film232. The sides of first and second polarizing films may be impacted by foreign materials in the display device or may be damaged by external shock. Also, the first and second polarizing films may be peeled off of a display panel due to external shock and bending tension. However, since the passivation film240_1extends over to, and covers, not only the adjacent sides of the first and second polarizing films231and232, but also parts of the first surfaces of the first and second polarizing films231and232, the passivation film240_1can prevent or substantially prevent the first and second polarizing films231and232from being peeled off of the display panel210and can protect the sides and the first surfaces of the first and second polarizing films231and232against external shock and foreign materials.

FIG. 7is a cross-sectional view of a display device according to another exemplary embodiment of the present disclosure; andFIG. 8is a cross-sectional view illustrating the display device ofFIG. 7in a bent state.

Referring toFIGS. 7 and 8, a display device3differs from the display device2ofFIGS. 5 and 6in that a passivation film240_2of a display module200_2extends over to, and covers, not only the adjacent side of a first polarizing film231, but also a part of a first surface of the first polarizing film231.

The passivation film240_2may cover the side of the first polarizing film231that is aligned with the boundary between a bending area BA and a main area MA and a part of the first surface of the first polarizing film231. Since the passivation film240_2extends over to, and covers, not only the adjacent side of the first polarizing film231, but also a part of the first surface of the first polarizing film231, the passivation film240_2can prevent or substantially prevent the first polarizing film231from being peeled off of a display panel210and can protect the side and the first surface of the first polarizing film231against external shock and foreign materials.

FIG. 9is a cross-sectional view of a display device according to another exemplary embodiment of the present disclosure; andFIG. 10is a cross-sectional view illustrating the display device ofFIG. 9in a bent state.

Referring toFIGS. 9 and 10, a display device4differs from the display device2ofFIGS. 5 and 6in that a passivation film240_3of a display module200_3extends over to, and covers, not only the adjacent side of a second polarizing film232, but also a part of a first surface of the second polarizing film232.

The passivation film240_3may cover the adjacent side of the second polarizing film232that is aligned with the boundary between a bending area BA and a sub-area SA and a part of the first surface of the second polarizing film232. Since the passivation film240_3extends over to, and covers, not only the side of the second polarizing film232, but also a part of the first surface of the second polarizing film232, the passivation film240_3can prevent or substantially prevent the second polarizing film232from being peeled off of a display panel210and can protect the side and the first surface of the second polarizing film232against external shock and foreign materials.

FIG. 11is a cross-sectional view of a display device according to another exemplary embodiment of the present disclosure; andFIG. 12is a cross-sectional view illustrating the display device ofFIG. 11in a bent state.

Referring toFIGS. 11 and 12, a display device5differs from the display device1ofFIGS. 1 through 4in that, in a display module200_4, a second polarizing film232_1of a polarizing film230_1and a second adhesive film222_1of a first adhesive member220_1extend to an end portion of a sub-area SA, and that a data driver chip250is disposed on a first surface of the second polarizing film232_1.

The second polarizing film232_1and the second adhesive film222_1may extend to an end portion of the sub-area SA. In this case, the area of the second polarizing film232_1for supporting the sub-area SA of a display panel210can be widened, and, as a result, the flatness of the display panel210can be further enhanced. The second polarizing film232_1and the second adhesive film222_1may include a via hole VIA. The data driver chip250may be connected to a connecting portion of the display panel210via the via hole VIA.

FIG. 13is a cross-sectional view of a display device according to another exemplary embodiment of the present disclosure; andFIG. 14is a cross-sectional view illustrating the display device ofFIG. 13in a bent state.

Referring toFIGS. 13 and 14, a display device6differs from the display device1ofFIGS. 1 through 4in that, in a display module200_5, a second polarizing film232_2of a polarizing film230_2and a second adhesive film222_2of a first adhesive member220_2extend to an end portion of a sub-area SA to cover a first surface of a data driver chip250.

The second polarizing film232_2and the second adhesive film222_2may extend to an end portion of the sub-area SA. The second polarizing film232_2and the second adhesive film222_2may cover the first surface of the data driver chip250.

The thickness of a part of the second polarizing film232_2that overlaps with the data driver chip250may differ from the thickness of a part of the second polarizing film232_2in the sub-area SA where the data driver chip250is not disposed, but the present disclosure is not limited thereto. In an embodiment, a first surface of the second polarizing film232_2may protrude in a thickness direction, for example, a third direction DR3, in an area where the second polarizing film232_2overlaps with the data driver chip250more than in an area where the data driver chip250is not disposed, but the present disclosure is not limited thereto. According to the exemplary embodiment ofFIGS. 13 and 14, since the second polarizing film232_2covers the first surface of the data driver chip250, damage to the data driver chip250caused by external shock or foreign materials can be minimized or reduced.

FIG. 15is a cross-sectional view of a display device according to another exemplary embodiment of the present disclosure; andFIG. 16is a cross-sectional view illustrating the display device ofFIG. 15in a bent state.

Referring toFIGS. 15 and 16, a display device7differs from the display device1ofFIGS. 1 through 4in that a data driver chip250is provided as a COF and is attached to a first surface of a display panel210via a flexible film260.

The flexible film260may be attached to one side of a display panel210. Although not specifically illustrated, a printed circuit board may be attached to a side of the flexible film260. The data driver chip250may be provided as a COF and may be electrically connected to the display panel210via the flexible film260, which is attached to a side of the display panel210. In an embodiment, a timing controller generating signals to be transmitted to the data driver chip250, which is mounted on the flexible film260, may be mounted on the printed circuit board.

FIG. 17is a cross-sectional view of a display device according to another exemplary embodiment of the present disclosure; andFIG. 18is a cross-sectional view illustrating the display device ofFIG. 17in a bent state.

Referring toFIGS. 17 and 18, a display device8differs from the display device1ofFIGS. 1 through 4in that there exists no second polarizing film232, and a passivation film240_4of a display module200_6is disposed on a first surface of a bending area BA of a display panel210and on a part of a first surface of a sub-area SA of the display panel210.

The passivation film240_4may be disposed on the first surface of the bending area BA of the display panel210and on a part of the first surface of the sub-area SA of the display panel210. In an embodiment, a passivation film240_4having a uniform modulus is disposed on the first surface of the bending area BA of the display panel210and on a part of the first surface of the sub-area SA of the display panel210, but the present disclosure is not limited thereto. In another example, the modulus of the passivation film240_4may be greater on the first surface of the bending area BA than on the first surface of the sub-area SA, in which case, as the display device8is bent, the passivation film240_4which is disposed on the first surface of the display panel210, can be bent in the bending area BA without bending stress because of its relatively large modulus in the bending area BA and can maintain the flatness of the display panel210in the sub-area SA because of its relatively small modulus in the sub-area SA.

FIG. 19is a cross-sectional view of a display device according to another exemplary embodiment of the present disclosure; andFIG. 20is a cross-sectional view illustrating the display device ofFIG. 19in a bent state.

Referring toFIGS. 19 and 20, a display device9differs from the display device8ofFIGS. 17 and 18in that a passivation film240_5of a display module200_7covers the entire adjacent side of a data driver chip250, which is disposed in a sub-area SA, and a part of a first surface of the data driver chip250.

The passivation film240_5may cover the entire adjacent side of the data driver chip250, which is disposed in the sub-area SA, and a part of the first surface of the data driver chip250. When the data driver chip250is not properly bonded to pad terminals (not illustrated) of a display panel210, the data driver chip250may be detached from a first surface of the display panel210. However, the passivation film240_5covers a part of the first surface of the data driver chip250and can thus prevent or substantially prevent the data driver chip250from being detached from and/or floating off of the first surface of the display panel210. Also, the passivation film240_5covers a side of the data driver chip250and can thus prevent or substantially prevent the data driver chip250from being damaged by external shock or foreign materials.

The passivation film240_5is illustrated as not covering the other side of the data driver chip250, but the present disclosure is not limited thereto. In an embodiment, the passivation film240_5may cover not only the adjacent side and the first surface of the data driver chip250, but also the other side of the data driver chip250, and can thus further protect the data driver chip against external shock or foreign materials so as to reduce any possible damage to the data driver chip250.

FIG. 21is a cross-sectional view of a display device according to another exemplary embodiment of the present disclosure, shown in a bent state.

Referring toFIG. 21, a display device10differs from the display device1ofFIGS. 1 through 4in that a spacer member130of a panel bottom structure100_1is provided in a gap formed in a bending area BA by a second surface of a display panel210and a first adhesive member110.

The display device10may further include the spacer member130, which is provided in the gap formed in the bending area BA by the second surface of the display panel210and the first adhesive member110. In an embodiment, the spacer member130may be a mandrel. The spacer member130may be inserted in the gap formed in the bending area BA. Thus, the spacer member130can alleviate shock that may be caused to the display panel210by stress generated in the bending area BA and external shock, can maintain the curvature of the display panel210, and can alleviate bending stress to some extent. Also, the spacer member130can alleviate shock that may be caused in response to the first adhesive member110and the second surface of the display panel210being placed in contact with each other in the bending area BA.

FIG. 22is a cross-sectional view of a display device according to another exemplary embodiment of the present disclosure; andFIG. 23is a cross-sectional view illustrating the display device ofFIG. 22in a bent state.

Referring toFIGS. 22 and 23, a display module200_8of a display device11may be scribed along the boundary between a main area MA and a bending area BA, the boundary between the bending area BA and a sub-area SA, and both edges of an end portion of the sub-area SA by one or more cutting members (e.g.,700ofFIG. 27A) that will be described later. In this case, the display device11may include burrs formed on first and second polarizing films231_1and232_3of a polarizing film230_3to have a thickness (e.g., a predetermined thickness), and an inner side of the first polarizing film231_1adjacent to the bending area BA and an inner side of the second polarizing film232_3adjacent to a data driver chip250may be inclined. Also, in an embodiment, the display device11may include scratches SC formed on a display panel210_1along the boundary between the main area MA and the bending area BA, the boundary between the bending area BA and the sub-area SA, and the boundary between the second polarizing film232_3and the data driver chip250.

FIG. 24is a cross-sectional view of a display device according to another exemplary embodiment of the present disclosure; andFIG. 25is a cross-sectional view illustrating the display device ofFIG. 24in a bent state.

Referring toFIGS. 24 and 25, a display module200_9of a display device12may have an entire bending area BA and one side of a sub-area SA irradiated with carbon dioxide (CO2) by one or more first laser members (e.g.,600ofFIG. 26A) that will be described later. The display device12differs from the display device11ofFIGS. 22 and 23in that the display device12further includes soot SO on a first surface of the bending area BA of a display panel210_2.

A method of manufacturing the display device1according to an exemplary embodiment of the present disclosure will hereinafter be described. A method of manufacturing a display device may be classified as a cell-based manufacturing method in which each individual display device is fabricated separately, and a mother substrate-based manufacturing method in which a plurality of display devices are concurrently (e.g., simultaneously) fabricated using a mother substrate and are separated later. The mother substrate-based manufacturing method may be more advantageous than the cell-based manufacturing method in terms of processing time and cost.

In an exemplary embodiment, a mother substrate300may be a rigid substrate formed of glass or quartz or a film including PET. Each display module200may be disposed on the surface of the mother substrate300, and a polarizing film230may be disposed on the entire surface of each display module200and may be attached to a first surface of each display module200via a first adhesive member220. In an exemplary embodiment, the polarizing film230may include main areas MA, sub-areas SA, and bending areas BA disposed between the main areas MA and the sub-areas SA. By partially removing the polarizing film230from the bending areas BA of the display panel210, the first polarizing films231and the second polarizing films232may be separated. The first polarizing films231may be disposed on first surfaces of the main areas MA of the display panel210, and the second polarizing films232may be disposed on first surfaces of the sub-areas SA of the display panel210.

In an embodiment, the separation of the first polarizing films231and second polarizing films232may include weakening the adhesive force of the first adhesive member220, scribing along both edges of each bending area BA and both edges of each area where a data driver chip250is to be disposed, and partially removing the polarizing film230from each scribed region.

FIGS. 26A and 26Bare perspective views illustrating examples of the step of weakening the adhesive force of a first adhesive member as performed in a method of manufacturing a display device according to an exemplary embodiment of the present disclosure. When the mother substrate-based manufacturing method is used, main areas MA, bending areas BA, or sub-areas SA of cells (or display modules200) that are adjacent to one another in a first direction DR1may be adjacent to one another.

Referring toFIG. 26A, the display modules200may be disposed on the entire top surface of the mother substrate300. A first laser member600may be placed above the display modules200. The first laser member600may apply carbon dioxide to an adhesive member in a desired area and may thus weaken the adhesive force of the adhesive member. In an exemplary embodiment, the first laser member600may apply carbon dioxide to the entire bending areas BA and parts of the sub-areas SA. The first laser member600may apply carbon dioxide, from above the display modules200, to the bending areas BA of cells that are adjacent to one another in the first direction DR1and parts of the sub-areas SA of the cells along the first direction DR1. In an embodiment, the first laser member600may weaken the adhesive forces of the first and second adhesive films221and222by moving only once over the bending areas BA of cells that are adjacent to one another in the first direction DR1and over parts of the sub-areas SA of the cells.

The example ofFIG. 26Bdiffers from the example ofFIG. 26Ain that multiple first laser members600are placed above the display modules200along a second direction DR2. According to the example ofFIG. 26B, the first laser members600can weaken the adhesive forces of the first and second adhesive films221and222not only in the bending areas BA and the sub-areas SA of cells that are adjacent to one another in the first direction DR1, but also in the bending areas BA and the sub-areas SA of cells that are adjacent to one another in the second direction DR2, by moving only once over the bending areas BA and the sub-areas SA of all the cells.

FIGS. 27A through 27Dare perspective views illustrating methods of manufacturing a display device according to exemplary embodiments and modified examples of the present disclosure. Specifically,FIGS. 27A through 27Dillustrate examples of the step of scribing a polarizing film230along the boundaries between the main areas MA and the bending areas BA, the boundaries between the bending areas BA and the sub-areas SA, and the edges of an end portion of each of the sub-areas SA with one or more cutting members700or701.

Referring toFIG. 27A, the polarizing film230may be scribed along the boundaries between the main areas MA and the bending areas BA, the boundaries between the bending areas BA and the sub-areas SA, and the edges of the end portion of each of the sub-areas SA by a cutting member or knife700. In an embodiment, the knife700may be a heat knife having a higher melting point than the polarizing film230, but the present disclosure is not limited thereto. As described above, since the boundaries between the main areas MA and the bending areas BA, the boundaries between the bending areas BA and the sub-areas SA, and the edges of the end portion of each of the sub-areas SA extend across cells that are adjacent to one another in the first direction DR1, the knife700can continuously scribe the polarizing film230and the first adhesive member220along the first direction DR1without interruption.

The example ofFIG. 27Bdiffers from the example ofFIG. 27Ain that multiple cutting members or knives700are used. Specifically, multiple knives700may be placed above the display modules200along the second direction DR2.

Even in this case, since the boundaries between the main areas MA and the bending areas BA, the boundaries between the bending areas BA and the sub-areas SA, and the edges of the end portion of each of the sub-areas SA extend across cells that are adjacent to one another in the first direction DR1, the knives700can continuously scribe the polarizing film230and the first adhesive member220along the first direction DR1without interruption. Also, since multiple knives700are placed along the second direction DR2, multiple cells that are adjacent to one another in the second direction DR2can be scribed at the same time.

Referring toFIG. 27C, the polarizing film230may be scribed along the boundaries between the main areas MA and the bending areas BA, the boundaries between the bending areas BA and the sub-areas SA, and the edges of the end portion of each of the sub-areas SA by a second laser member701. The second laser member701may be an ultraviolet (UV) laser, but the present disclosure is not limited thereto. As described above, since the boundaries between the main areas MA and the bending areas BA, the boundaries between the bending areas BA and the sub-areas SA, and the edges of the end portion of each of the sub-areas SA extend across cells that are adjacent to one another in the first direction DR1, the second laser member701can continuously scribe the polarizing film230and the first adhesive member220along the first direction DR1without interruption.

The example ofFIG. 27Ddiffers from the example ofFIG. 27Cin that multiple second laser members701are used. Specifically, multiple second laser members701may be placed above the display modules200along the second direction DR2. Even in this case, since the boundaries between the main areas MA and the bending areas BA, the boundaries between the bending areas BA and the sub-areas SA, and the edges of the end portion of each of the sub-areas SA extend across cells that are adjacent to one another in the first direction DR1, the second laser members701can continuously scribe the polarizing film230and the first adhesive member220along the first direction DR1without interruption. Also, since multiple second laser members701are placed along the second direction DR2, multiple cells that are adjacent to one another in the second direction DR2can be scribed at the same time.

After performing scribing, as described above with reference toFIGS. 26A through 27D, the polarizing film230may be removed from each scribed region, thereby separating the first polarizing films231and the second polarizing films232. Thereafter, the passivation films240may be further disposed on first surfaces of the bending areas BA, and the data driver chips250may be further disposed on first surfaces of the end portions of the sub-areas SA. The passivation films240may be disposed between the first polarizing films231and the second polarizing films232, and the second polarizing films232may be disposed between the data driver chips250and the bending areas BA.

Thereafter, cells are separated from the mother substrate300, thereby obtaining each individual display module200. Thereafter, each individual display module200may be bent in a bending direction, thereby obtaining a flexible display device.

The aspects and effects of the embodiments are not limited by the contents exemplified above, and other various aspects and effects are included in the present specification.