Lamination apparatus and method of manufacturing display device using the same

A lamination apparatus including a first stage including a first body portion and an accommodation portion disposed on a bottom surface of the first body portion, a second stage disposed to face the first stage, and a jig device disposed between the first stage and the second stage, the jig device including a second body portion and at least one jig portion, in which the at least one jig portion has one end fastened to the second body portion and the other end having a rounded shape.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from and the benefit of Korean Patent Application No. 10-2019-0032902, filed on Mar. 22, 2019, which is hereby incorporated by reference for all purposes as if fully set forth herein.

BACKGROUND

Field

Exemplary embodiments of the invention relate generally to a lamination apparatus and a method of manufacturing a display device using the same.

Discussion of the Background

The display device market has been developed for a flat panel display (FPD). In flat panel displays, an area thereof may be easily increased while thickness and weight may be decreased.

Flat panel displays may include a liquid crystal display (LCD), a plasma display panel (PDP), an organic light emitting display (OLED), and the like.

However, recently, curved panel displays (CPDs) that have a curvature in a partial area thereof have been developed in FPDs, and an additional member or sensor may be disposed on a curved surface of a display. In CPDs, a larger amount of space may be utilized than that of FPDs, and a variety of functions may be provided through sensors disposed on a curved surface.

Accordingly, CPDs have been developed as a next-generation display device, and thus, a variety of evaluation apparatuses or manufacturing apparatuses related to a curved substrate or a curved panel are required.

More particularly, when joining a cover window having a curved shape to a panel having a flat shape in a CPD, since the cover window and the panel have different shapes, it is not easy to join a curved surface part with a conventional joining method.

SUMMARY

A lamination apparatus constructed according to exemplary embodiments of the invention includes a pivotable jig device and is capable of joining a curved-shaped member to a flat-shaped member.

Exemplary embodiments also provide a method of manufacturing a display device, which easily joins a first member and a second member having different shapes by using the lamination apparatus without a gap therebetween.

A lamination apparatus according to an exemplary embodiment includes a first stage including a first body portion and an accommodation portion disposed on a bottom surface of the first body portion, a second stage disposed to face the first stage, and a jig device disposed between the first stage and the second stage, the jig device including a second body portion and at least one jig portion, in which the at least one jig portion has one end fastened to the second body portion and the other end having a rounded shape.

The accommodation portion may be recessed upwardly from a portion of the bottom surface of the first body portion, and an outer part of the accommodation portion may have a curved surface.

The first stage may further include a first sealing portion surrounding the outer part of the accommodation portion.

The first stage may further include a fixing device disposed on a top surface of the first body portion overlapping with the accommodation portion.

The jig portion may include a first jig portion including a first end fastened to the second body portion and a second end opposite to the first end, and a second jig portion including a third end facing the first end of the first jig portion and a fourth end opposite to the third end.

A width from the second end of the first jig portion to the fourth end of the second jig portion along a first direction may be less than a width of the accommodation portion measured in the first direction.

The first jig portion and the second jig portion may be configured to pivot by a predetermined radius on a central axis located in the second body portion, to which the first end of the first jig portion and the third end of the second jig portion are fastened.

The jig device may further include a pressure device configured to apply a first pressure between the first jig portion, the second jig portion, and the first stage.

The second stage may include a first sub-stage disposed below the first jig portion, and a second sub-stage spaced apart from the first sub-stage and disposed below the second jig portion.

The first sub-stage may include a fixing area, in which at least a portion thereof is curved, and the fixing area may face the second end of the first jig portion.

The second stage may further include a second sealing portion disposed on the fixing area of the first sub-stage.

A method of manufacturing a display device according to another exemplary embodiment includes preparing a first member on a first stage, the first member having at least one curved portion, preparing a second member on a jig device and moving the jig device, such that the second member faces the first member, and fixing the first stage and the jig device and joining the first member and the second member.

The jig device may include a body portion and at least one jig portion having one end fastened to the body portion and the other end having a rounded shape, and the jig portion may pivot by a predetermined radius on a central axis disposed in the body portion.

Preparing the second member on the jig device may include forming an adhesive sheet on the jig device, and placing the second member on the adhesive sheet.

Preparing the second member on the jig device and moving the jig device may further include bending the second member by pivoting the jig portion, such that a central part of the second member is placed below both ends thereof, and unbending the second member to be disposed adjacent to the first member while being spaced apart therefrom.

Fixing the first stage and the jig device and joining the first member and the second member may include applying a first pressure between the first stage and the jig device, and applying a second pressure higher than the first pressure between the jig device and the adhesive sheet.

The first pressure may be within a range of 10 Pa to 10 kPa, and the second pressure may be within a range of 0.1 MPa to 0.9 MPa.

The first stage may further include a fixing device forming a vacuum at least in a partial area of a bottom surface, and the first member may be provided on the bottom surface of the first stage and the fixing device may form a vacuum between the first member and the bottom surface.

The first member may include one surface parallel to the bottom surface of the first stage and a first peripheral part bent downward from the one surface, and a width of the one surface of the first member along a second direction may be less than a width of the first member measured in the second direction.

The first member may further include a second peripheral part bent downward from the one surface, and a width between opposing ends of the first and second peripheral parts of the first member may be less than the width of the first member measured in the second direction.

DETAILED DESCRIPTION

FIG. 1is a perspective view of a lamination apparatus according to an exemplary embodiment.FIG. 2is a cross-sectional view of the lamination apparatus taken along line I-I′ ofFIG. 1.

A lamination apparatus1000according to an exemplary embodiment may include a first stage100, a second stage200, and a jig device300. The lamination apparatus1000may join a first member to a second member, which are prepared on the first stage100and the jig device300, respectively. In particular, since the first stage100provided with the first member and the jig device300provided with the second member have outer surfaces having curvatures, the lamination apparatus1000may easily join a flat member20(refer toFIG. 10) to a curved part of a curved member10(refer toFIG. 8).

In the lamination apparatus1000according to the illustrated exemplary embodiment, the first stage100and the jig device300have curved shapes that conform to the shape of the curved member10, which is an object to be joined, such that product defects that may occur from joining the curved member10and the flat member20may be prevented. In general, when the curved member10and the flat member20having different shapes are to be joined, the flat member20and the curved member10may be inaccurately joined, such as not mutually being aligned or forming a gap therebetween. A joining method using the lamination apparatus1000according to an exemplary embodiment includes an operation of preforming the flat member20to have a predetermined shape, such that the flat member20may be prevented from being damaged when the flat member20and the curved member10come into contact with each other. Hereinafter, the lamination apparatus1000will be described in more detail.

Referring toFIGS. 1 and 2, the lamination apparatus1000may include the first stage100, the second stage200facing the first stage100, and the jig device300disposed therebetween.

The first stage100may be provided with the first member, which is an object to be joined during the joining process using the lamination apparatus1000. The first stage100may be an upper stage located above the jig device300in the lamination apparatus1000. The first stage100may include a first body portion110to provide a space in which the first member may be prepared. A shape of the first body portion110is not particularly limited. In the drawings, it is shown that sides of the first body portion110extend in a first direction (X-axis direction) and a second direction (Y-axis direction), and corners thereof have angular shapes. However, the inventive concepts are not limited thereto, and in some exemplary embodiments, the first body portion110may have rounded or circular corners.

According to an exemplary embodiment, the first stage100may include an accommodation portion120to which the curved member10is provided. The accommodation portion120may be formed on one surface of the first stage100, in particular, a bottom surface of the first body portion110. The accommodation portion120may be formed as a recess from a portion of the bottom surface of the first body portion110in an upper direction. The first member provided to the first stage100may be fixed to the accommodation portion120, and may be joined to the second member provided to the jig device300.

As described above, the first member may be the curved member10(seeFIG. 8) and may have a partial area having a curved shape. In an exemplary embodiment, the accommodation portion120may have a shape, in which an outer part of the recessed area upward from the bottom surface of the first body portion110is rounded with a certain curvature. The curved member10to be joined using the lamination apparatus1000may have a partial area having a flat surface, and an outer part formed to be curved from the flat surface in one direction, for example, in a downward direction. The accommodation portion120of the first stage100may have a partial area, which has a certain curvature and a rounded shape, such that the curved member10having the curved outer part may be fixed. The curvature of the rounded area of the accommodation portion120is not particularly limited. The area of the accommodation portion120may be designed according to a shape of the outer part of the curved member10to be joined, such that the curved member10may be fixed to the accommodation portion120without a gap therebetween.

According to an exemplary embodiment, the first stage100may include a fixing device150for fixing the curved member10provided to the accommodation portion120. The first stage100may fasten the provided curved member10to the accommodation portion120, or may fix the curved member10to the accommodation portion120using the fixing device150. A shape of the accommodation portion120may coincide with that of the curved member10. When the accommodation portion120and the curved member10are physically attached and fixed to each other, an outer surface of the curved member10may be damaged during an operation of providing the curved member10to the first stage100. As such, the first stage100may include the additional fixing device150, and may fix the curved member10provided to the accommodation portion120without a gap.

A type of the fixing device150is not particularly limited. For example, the fixing device150may be a mechanical fixing portion, which is disposed on one side adjacent to the accommodation portion120and fixes the curved member10, or may be an electrostatic generator using static electricity between the accommodation portion120and the curved member10. In an exemplary embodiment, the fixing device150may be a vacuum-forming device, which forms vacuum pressure between the accommodation portion120and the curved member10provided thereto.

FIG. 3is a schematic diagram illustrating an operation of a fixing device of a first stage according to an exemplary embodiment.

Referring toFIG. 3, the fixing device150according to an exemplary embodiment may be disposed on one surface of the first stage100, for example, a top surface of the first body portion110. The first stage100is formed to have a predetermined thickness, such that the accommodation portion120and the fixing device150may be spaced apart from each other. The fixing device150may provide vacuum pressure VP to the accommodation portion120through a space spaced apart from the accommodation portion120. In the joining process using the lamination apparatus1000, when the curved member10is provided to the accommodation portion120, the fixing device150may provide the vacuum pressure VP to the accommodation portion120, and the vacuum pressure VP may be transferred between the accommodation portion120and the curved member10. The vacuum pressure VP transferred therebetween may fix the curved member10without a gap from the accommodation portion120. Accordingly, the curved member10provided to the first stage100may be fixed to the accommodation portion120and joined to the second member provided to the jig device300which will be described below, for example, the flat member20, at a precise position. However, as described above, the type of the fixing device150is not particularly thereto.

The first stage100may further include a first sealing portion170(seeFIG. 4), which seals a space between the first stage100and the jig device300during the joining process. According to an exemplary embodiment, the first stage100may include the first sealing portion170disposed to surround a peripheral part of the accommodation portion120.

FIG. 4is a plan view of the first stage according to an exemplary embodiment.

FIG. 4shows a bottom surface of the first stage100when viewed from below according to an exemplary embodiment. Referring toFIG. 4, the first stage100according to an exemplary embodiment may include the first sealing portion170. In the joining process using the lamination apparatus1000, the first sealing portion170may seal a space among the first stage100, the jig device300, and the second stage200, which are joined to one another. As will be described below, the lamination apparatus1000may compress and join the curved member10and the flat member20at high pressure. In this case, the first sealing portion170may be disposed, such that high pressure provided after the curved member10comes into contact with the flat member20, does not leak into the space between the first stage100and the jig device300or the second stage200.

The first sealing portion170is disposed to surround the peripheral part of the first accommodation portion120so as to come into partial contact with the flat member20or an adhesive sheet30(refer toFIG. 8), which will be described below, when the curved member10comes into contact with the flat member20. The first sealing portion170may function as a partition, which seals a space between the curved member10and the flat member20or the adhesive sheet30, in an area where the first sealing portion170makes contact. However, the inventive concepts are not limited thereto.

Referring back toFIGS. 1 and 2, the jig device300is disposed between the first stage100and the second stage200, which will be described below. The jig device300may be provided with the flat member20, which is to be joined to the curved member10. The jig device300may include a providing portion350corresponding to the accommodation portion120of the first stage100. When the flat member20is prepared at the providing portion350, and the first stage100is joined to the jig device300, the curved member10of the accommodation portion120may come into contact with the flat member20of the providing portion350. However, the inventive concepts are not limited thereto.

The jig device300according to an exemplary embodiment includes a first jig portion310, a second jig portion320, and a second body portion330. The first jig portion310and the second jig portion320are fastened to the second body portion330, and may pivot in one direction on the second body portion330. The providing portion350of the jig device300may be substantially disposed on top surfaces of the first jig portion310and the second jig portion320.

In an exemplary embodiment, each of the first jig portion310and the second jig portion320may include one end fastened to the second body portion330, and the other end opposite to the one end having a rounded shape. The first jig portion310and the second jig portion320have substantially the same shape, and the one ends fastened to the second body portion330may be disposed to face each other. More particularly, the first jig portion310and the second jig portion320may have mutually symmetrical structures with respect to the second body portion330. As such, hereinafter, the jig device300will be described with reference to the first jig portion310as an example.

The first jig portion310includes a first end311fastened to the second body portion330, and a second end312opposite to the first end311. A top surface between the first end311and the second end312may form a flat surface. Since the flat member20is prepared on the first jig portion310, a top surface of the first jig portion310is formed to be flat. On the other hand, a bottom surface between the first end311and the second end312has a partially flat area, and a bottom surface of the first end311may have a curvature. As will be described in more detail below, since the first jig310may pivot on a central axis located on the second body portion330, a bottom surface of the first end311fastened to the second body portion330may have a curved shape along a turning radius. Accordingly, in the first jig portion310, the second end312may have a shape protruding from the curved-shaped bottom surface. However, the inventive concepts are not limited thereto.

The first end311may be fastened to the second body portion330, and may form a parallel side surface along one direction in a cross-sectional view. The side surface of the first end311may be in contact with the side surface of the first end of the second jig portion320while facing the same. The first end311may pivot on a central axis to be spaced apart from the first end of the second jig portion320.

The second end312may have a rounded shape having a predetermined curvature. As will be described in more detail below, the second end312may place the flat member20to face the curved area of the curved member10prepared at the accommodation portion120in the joining process of the lamination apparatus1000. The second end312of the first jig portion310, which has the rounded shape, may allow the flat member20to face the curved portion of the curve surface member10to facilitate the joining process. Accordingly, it is possible to prevent a space from being formed in the curved portion when the curved member10is joined to the flat member20. The rounded shape of the second end312is not particularly limited. As in the accommodation portion120, the shape of the second end312may be designed according to the shape of the curved portion of the curved member10.

The second body portion330forms a basic frame of the jig device300. The second body portion330may provide a space, in which the first jig portion310and the second jig portion320are fastened, and the flat member20is prepared on the jig portions310and320in the joining process of the lamination apparatus1000. Also, the central axis, where the first jig portion310and the second jig portion320are fastened to and pivot thereon, may be located in the second body portion330. A detailed description thereof will be described with reference to other drawings.

The jig device300according to an exemplary embodiment may move in one direction, for example, in a vertical direction, which is a third direction (Z-axis direction) spaced apart from the first stage100. In the joining process of the lamination apparatus1000, the jig device300may move in the vertical direction, such that the flat member20prepared on the jig device300may face the curved member10. The jig device300moves before the curved member10is joined to the flat member20, such that the curved member10and the flat member20face each other, and the second stage200, which will be described below, fixes the first stage100and the jig device300. Afterwards, pressure is transferred to a space therebetween, such that the curved member10and the flat member20may be joined to each other. However, the inventive concepts are not limited thereto.

The jig device300may further include other members arranged on the second body portion330. For example, a pressure forming device transferring high pressure between the second body portion330and the first stage100when they are joined, and a temperature controller adjusting a temperature of the flat member20prepared on the top surfaces of the jig portions310and320may be further disposed on the second body portion330. However, the inventive concepts are not limited thereto.

According to an exemplary embodiment, in the jig device300, the first jig portion310and the second jig portion320may pivot on the central axis located at the second body portion330in a certain radius.

FIG. 5is a schematic diagram illustrating an operation of the jig device according to an exemplary embodiment.

In the jig device300shown inFIG. 5, dotted lines indicate an initial state of the jig portions310and320when not pivoted, and solid lines indicate the jig portions310and320when pivoted along a certain radius.

Referring toFIG. 5, the first jig portion310and the second jig portion320are fastened to the second body portion330, and the central axis extending in one direction may be located in the fastened area. The first jig portion310and the second jig portion320may pivot by a certain radius with respect to the central axis.

The flat member20prepared on the jig device300may be prepared, while a partial area thereof is bent before facing the curved member10to be easily joined to a curved outer surface of the curved member10. The flat member20may access the curved member10while the partial area is bent, and then may face the curved member10as the bent area is unbent. Here, the flat member20may be prepared on the jig portions310and320, and the flat member20may be bent as the jig portions310and320pivot by a certain radius. The jig device300according to an exemplary embodiment includes a plurality of jig portions310and320, which are pivotable by a certain radius, such that the flat member20may be formed while a partial area thereof is bent in the joining process of the lamination apparatus1000. Both ends of the flat member20prepared while being bent are located on the rounded second ends312of the jig portions310and320, and may face the curved outer part of the curved member10as the jig portions310and320pivot again in opposite directions.

More particularly, when a space between the curved outer parts of the curved member10is smaller than a width of the curved member10, it may not be easy to join the flat member20to the curved member10. However, the lamination apparatus1000according to an exemplary embodiment may bend the flat member20to have a smaller width than the space between the curved outer parts of the curved member10. Afterwards, the flat member20is unbent again, such that the curved member10and the flat member20may be mutually joined at a precise position. A more detailed description will be set forth below.

In an exemplary embodiment, the area of the second body portion330, to which the first jig portion310and the second jig portion320are fastened, may move in one direction, for example, in the vertical direction which is the third direction (Z-axis direction) spaced apart from the first stage100A portion of the second body portion330, in which the central axis is located, may be vertically moved, such that the first jig portion310and the second jig portion320may pivot by a certain radius.

As shown in the drawings, as the second body portion330moves in the vertical direction, the central axis of the first jig portion310and the second jig portion320may move, such that the first jig portion310and the second jig portion320may pivot by a certain radius on the central axis. However, the inventive concepts are not limited thereto. For example, in some exemplary embodiments, while the second body portion330may not move, the first jig portion310and the second jig portion320may pivot on the central axis.

Referring back toFIGS. 1 and 2, the second stage200faces the first stage100, and is disposed below the jig device300. The second stage200may be a lower stage of the lamination apparatus1000. The second stage200may fix the jig device300simultaneously while sealing the gap between the curved member10provided on the first stage100and the flat member20provided on the jig device300when the curved member10and the flat member20are joined. In the joining process using the lamination apparatus1000, the second stage200may come into contact with and fix the first stage100and the jig device300below the jig device300.

According to an exemplary embodiment, the second stage200may include a plurality of sub-stages210and220spaced apart from each other. The sub-stages210and220may include a first sub-stage210and a second sub-stage220. However, the inventive concepts are not limited to a particular number of the sub-stages, and in some exemplary embodiments, the second stage200may include a larger number of sub-stages210and220that are separable from one another. The number of the sub-stages210and220may vary according to the shape of the jig portions310and320of the jig device300.

The first sub-stage210and the second sub-stage220may be spaced apart in the first direction (X-axis direction). As shown inFIG. 2, the first sub-stage210and the second sub-stage220may be arranged to correspond to the first jig portion310and the second jig portion320, respectively. The first sub-stage210and the second sub-stage220may be disposed below the jig portions310and320of the jig device300, respectively, and the second body portion330of the jig device300may be located in a space therebetween. The first sub-stage210and the second sub-stage220have substantially the same shape, and may have a mutually symmetrical structure with respect to the space therebetween. Hereinafter, a structure and an operation of the first sub-stage210corresponding to the first jig portion310will be exemplarily described with reference to other drawings.

FIG. 6is a schematic diagram illustrating an operation of the second stage according to an exemplary embodiment.

FIG. 6illustrates a state in which the first stage100, the jig device300, and the second stage200are joined. Referring toFIGS. 2 and 6, a fixing area251,252and a second sealing portion270may be disposed on the first sub-stage210. The fixing area251,252may be an area of the first sub-stage210coming into contact with and fixing the first stage100and the jig device300in the joining process of the lamination apparatus1000. The fixing area251,252may include a first fixing area251, which comes into contact with the first stage100, and a second fixing area252which comes into contact with the first jig portion310.

In an exemplary embodiment, the first fixing area251may have a rounded shape having a predetermined curvature, and the second fixing area252may have a substantially flat top surface. The first sub-stage210is disposed to correspond to the first jig portion310as described above. When the second stage200is joined to the jig device300and the first stage100, the second fixing area252of the first sub-stage210may come into contact with the first body portion110of the first stage100that protrudes toward the outside of the first jig portion310, and the first fixing area251may be partially overlapped with the curved outer part of the first jig portion310. More particularly, the second fixing area252having the flat top surface may come into contact with the bottom surface of the first body portion110of the first stage100, and the first fixing area251may face the curved outer part of the first jig portion310. Since the curved member10and the flat member20may be located between the first jig portion310and the first sub-stage210, the first fixing area251may not come into direct contact with the first jig portion310. In some exemplary embodiments, the first fixing area251may come into contact with the curved member10, and may face a bottom surface of the first jig portion310.

A shape of the first fixing area251may vary according to the shape of the first jig portion310. Since the shape of the curved outer part of the first jig portion310varies according to the shape of the curved member10joined using the lamination apparatus1000as described above, the shape of the first fixing area251may also vary according to the shape of the curved member10. However, the inventive concepts are not limited thereto.

Side surfaces of the first sub-stage210and the second sub-stage220spaced apart from each other may be formed to correspond to the second body portion330of the jig device300. In the joining process of the lamination apparatus1000, the side surfaces of the sub-stages210and220may come into contact with the second body portion330of the jig device300without a gap therebetween. Accordingly, in the high pressure process of joining the curved member10to the flat member20, a high pressure may not leak through the space therebetween. However, the inventive concepts are not limited thereto.

The second sealing portion270may be disposed on each of the sub-stages210and220of the second stage200. In an exemplary embodiment, the second sealing portion270may be disposed in a portion of each of the sub-stages210and220which comes into contact with members to be joined, such as s, the jig portions310and320. In the joining process of the lamination apparatus1000, the second sealing portion270may seal a space among the first stage100, the jig device300, and the second stage200, which are joined to one another. In the drawings, it is shown that the second sealing portion270is disposed only on the first fixing area251. However, the inventive concepts are not limited thereto. In some exemplary embodiments, the second sealing portion270may also be disposed on the second fixing area252and at least one side surface of the first sub-stage210.

As shown inFIG. 6, when the first stage100, the jig device300, and the second stage200are joined, they may be spaced apart at a certain interval. For example, the interval may be within a range of 0.5 mm to 1.5 mm, without being limited thereto. High pressure is transferred to a space therebetween, which may adjoin the curved member10and the flat member20to each other. In the high pressure process, the second stage200may prevent the pressure from leaking to the outside from the lamination apparatus1000, and may fix the jig device300to the first stage100. As described above, when the curved member10and the flat member20having different shapes are joined, a contact area therebetween may be misaligned. The lamination apparatus1000according to an exemplary embodiment includes the first stage100, which allows the curved-shape member10and the flat member20to come into contact with each other, and the second stage200that fixes the jig device300. Also, since the second stage200includes the second sealing portion270which seals the space therebetween, it is possible to prevent or minimize a failure that may occur during the joining process of the lamination apparatus1000.

Hereinafter, a joining process using the lamination apparatus1000according to an exemplary embodiment will be described in detail.

FIG. 7is a flowchart illustrating the joining process using the lamination apparatus according to an exemplary embodiment.

Referring toFIG. 7, the joining process using the lamination apparatus1000may include a first operation of preparing the first member, in particular, the curved member10on the first stage100, a second operation of preparing the second member, in particular, the flat member20on the jig device300, and moving the jig device300to allow the flat member20to face the curved member10, and a third operation of fixing the first stage100and the jig device300, and joining the curved-shape member10to the flat member20.

According to an exemplary embodiment, in order to mutually join the curved member10and the flat member20having different shapes, the joining process using the lamination apparatus1000may include an operation of bending a partial area of the flat member20by pivoting the jig portions310and320of the jig device300. Accordingly, the curved-shape member10having the curved partial area and the flat member20may be easily joined without a gap therebetween. The joining process using the lamination apparatus1000will be described in detail with reference to other drawings.

FIGS. 8 to 16are cross-sectional views illustrating the joining process using the lamination apparatus according to an exemplary embodiment.

Referring toFIG. 8, the first member, for example, the curved member10is provided on the first stage100. The curved member10may be provided to the accommodation portion120of the first stage100. In an exemplary embodiment, when the curved member10is provided to the accommodation portion120of the first stage100, the fixing device150may fix the curved member10by forming the vacuum pressure VP between the curved member10and the accommodation portion120. The vacuum pressure VP formed by the fixing device150fixes the curved member10while a top surface of the curved member10is in contact with a bottom surface of the accommodation portion120. Afterwards, the flat member20may be joined to the fixed curved member10at a precise position. Detailed descriptions of the fixing device150have been made above, and thus, will be omitted.

As described above, the first member, that is, the curved member10may have a partially curved area. As shown in the drawing, the curved member10may include one surface parallel to the bottom surface of the first stage100, and a peripheral part bent downward from the one surface. The curved member10may include the flat one surface and the peripheral part having a curved shape. The lamination apparatus1000according to an exemplary embodiment may join the curved member10to the flat member20without a gap through pivoting of the jig portions310and320even when the peripheral part of the curved member10has a curved shape.

In an exemplary embodiment, a width of the flat surface of the curved member10may be less than a width of the curved member10. In this case, the width may be measured in one direction, for example, from left to right. More particularly, the curved member10may have a shape in which the peripheral part protrudes from the flat surface. In the first jig portion310and the second jig portion320of the jig device300, the second end312may have a rounded shape to correspond to the protruding peripheral part of the curved member10. In a following operation, the flat member20prepared on the jig device300may be disposed on the rounded area of the second end312and joined to be corresponding to the peripheral part of the curved member10.

According to an exemplary embodiment, the width between both bent ends of the peripheral part of the curved member10may be less than the width of the curved member10. More particularly, the ends of the peripheral part of the curved member10may be formed to be recessed toward the inside of the curved member10. An opening area formed by the ends of the peripheral part of the curved member10may be smaller than a width between outer sides thereof. As described below, the lamination apparatus1000according to an exemplary embodiment may partially bend the flat member20by pivoting the jig portions310and320and may join the flat member20to the open area having a width smaller than the width of the curved member10. A more detailed description will be set forth below.

Next, the second member, for example, the flat member20, is prepared on the jig device300. In an exemplary embodiment, the flat member20may be disposed on the adhesive sheet30disposed above the jig device300. Referring toFIG. 9, the adhesive sheet30is prepared on the jig device300. The adhesive sheet30may be a double-sided adhesive sheet, in which a bottom surface thereof comes into contact with the jig device300, and a top surface, to which the flat member20is disposed. Adhesion of the adhesive sheet30may be equal to or higher than 0.05 N/mm2.

The adhesive sheet30may be disposed to cover the top surfaces of the first jig portion310and the second jig portion320, and outer surfaces of the rounded ends, that is, the second ends312. As shown in the drawing, the adhesive sheet30may be partially disposed on bottom surfaces of the second ends312while covering the rounded outer surfaces of the second ends312. In an exemplary embodiment, the adhesive sheet30may include an elastic material, and a partial area thereof may be bent or elongated according to pivoting of the jig portions310and320. For example, the adhesive sheet30may have an elongation rate within a range of 50% to 300%.

When the jig portions310and320of the jig device300pivot on the central axis, an area of the adhesive sheet30may be partially elongated or contracted. Since the flat member20disposed on the adhesive sheet30may adhere to the top surface of the adhesive sheet30, the shape of the flat member20may be varied according to deformation of the adhesive sheet30. As such, to prevent the adhesive sheet30from being damaged by pivoting the jig portions310and320, the adhesive sheet30may include an elastic material.

When the adhesive sheet30includes the elastic material, in the operation of joining the curved member10to the flat member20, it is possible to uniformly join the curved member10to the flat member20in an area between the curved member10and the flat member20, and particularly, in a curved area of the curved member10, by applying high pressure to a space between the adhesive sheet30and the jig device300. A description thereof will be set forth below.

Referring toFIG. 10, the flat member20is prepared on the adhesive sheet30. The flat member20may be attached to the adhesive sheet30. In a following operation, when the adhesive sheet30is deformed according to pivoting of the jig portions310and320, the shape of the flat member20may be deformed at the same time. Although the flat member20is described as being prepared on the jig device300after preparing the curved member10on the first stage, a sequence thereof is not particularly limited. For example, in some exemplary embodiments, the curved member10may be prepared after preparing the flat member20.

Referring toFIG. 11, the jig device300moves such that the flat member20faces the curved member10. According to an exemplary embodiment, the operation of moving the jig device300may include an operation of bending the flat member20by pivoting the jig portions310and320, such that a central part thereof is located below both ends thereof, and an operation of unbending the flat member20so as to be located adjacent to the curved member10while being spaced apart therefrom.

As described above, since the peripheral part of the curved member10has a downwardly curved shape, the open area of the curved member10may be smaller than the width of the curved member10. When the flat member20is located to face the curved member10, the flat member20may need to be moved to the open area smaller than the width of the curved member10. As such, the lamination apparatus1000according to an exemplary embodiment may include the jig portions310and320, which are pivotable by a certain radius, and the joining process may include the operation of the bending the flat member20.

More particularly, the flat member20may be bent by pivoting the jig portions310and320in one direction, for example, in the upward direction which is the third direction (Z-axis direction) on the central axis. The flat member20disposed on the adhesive sheet30may be bent according to pivoting of the jig portions310and320, such that the central part thereof is located below the both ends. For example, the flat member20may have a convex shape toward the jig portions310and320when bent. Accordingly, a distance between the both ends of the flat member20may become less than the width of the open area of the curved member10.

Then, the flat member20is unbent and located to be adjacent to the curved member10while being spaced apart therefrom. In particular, the flat member20is inserted into the open area of the curved member10by moving the jig device300in an upward direction. When the flat member20is inserted into the open area, the flat member20is unbent by pivoting the jig portions310and320in an opposite direction, for example, in a downward direction. The above-described operations of the jig device300may be substantially continuously performed, such that the flat member20may be located to be adjacent to the curved member10while being spaced apart therefrom.

The operation of locating the flat member20to be spaced apart from the curved member10may be performed according to a preset reference alignment degree. In the operation of joining different members, when an alignment state thereof is imprecise, joining positions may become different to cause defects. Accordingly, the alignment degree may need to be precisely adjusted according to each of positions of the flat member20and the curved member10.

Referring toFIG. 12, the first stage100and the jig device300are fixed to each other. The fixing operation may be performed using the second stage200. The first sub-stage210and the second sub-stage220of the second stage200may move in the third direction (Z-axis direction) and may be located below the first jig portion310and the second jig portion320. As described above, the first fixing area251of the first sub-stage210may face the bottom surface of the first jig portion310, and the second fixing area252may come into contact with the first body portion110of the first stage100.

As shown in the drawing, since the jig device300disposes the curved member10and the flat member20to be spaced apart from each other, a space may be formed therebetween. In an exemplary embodiment, a width of the space may be within a range of 0.5 mm to 1.5 mm. However, the inventive concepts are not limited thereto. The curved member10and the flat member20may face each other while being spaced apart before being joined to each other.

The first fixing area251may face the bottom surface of the first jig portion310, and the curved member10and the flat member20may be located in the space therebetween. In some exemplary embodiments, the first fixing area251of the curved area may come into contact with the curved member10. As described above, the fixing areas250of the sub-stages210and220may be designed according to the curved shape of the curved member10.

Also, since the first stage100and the second stage200include the sealing portions170and270, respectively, the sealing portions170and270may be disposed in a contact area of the first stage100and the second stage200. The sealing portions170and270may seal an area between the first stage100and the second stage200, and an area between the second stage200and the jig device300. According to an exemplary embodiment, the sealing portions170and270may come into partial contact with the adhesive sheet30, and a partial area of the adhesive sheet30, which comes into contact with the sealing portions170and270, may form a partition between the curved member10and the flat member20. Accordingly, in a following operation, it is possible to prevent pressure applied therebetween from leaking.

Referring toFIGS. 13 and 14, the curved member10and the flat member20are joined. According to an exemplary embodiment, the operation of joining the curved member10to the flat member20may include an operation of applying a first pressure P1between the first stage100and the jig device300, and an operation of joining the curved member10to the flat member20by applying a second pressure P2higher than the first pressure P1between the jig device300and the adhesive sheet30.

More particularly, as shown inFIG. 13, the first pressure P1is applied to the space between the curved member10and the flat member20. In an exemplary embodiment, the first pressure P1may be within a range of 10 Pa to 10 kPa. However, the inventive concepts are not limited thereto. The first pressure P1may be lower than the second pressure P2. As the first pressure P1, which is relatively low, is applied to an area between the curved member10and the flat member20, an environment similar to a vacuum may be formed in a space therebetween. Accordingly, when the curve-shaped member10is joined to the flat member20by the applied second pressure P2in a following operation, it is possible to prevent bubbles or foreign substances from being generated therebetween.

Next, as shown inFIG. 14, the curved member10is joined to the flat member20by applying the second pressure P2, which is relatively high, between the jig device300and the adhesive sheet30. In an exemplary embodiment, the second pressure P2may be within a range of 0.1 MPa to 0.9 MPa, without being limited thereto.

The second pressure P2is applied below the adhesive sheet30disposed on the jig device300. When the relatively low first pressure P1is applied between the curved member10and the flat member20, and the relatively high second pressure P2is applied between the jig device300and the adhesive sheet30, the adhesive sheet30may be pushed out in an upward direction, such that the flat member20may be joined to the curved member10. In this case, since the adhesive sheet30includes an elastic material, the flat member20may be uniformly joined to the curved member10by the second pressure P2in an area that comes into contact with the adhesive sheet30.

More particularly, the curved peripheral part of the curved member10may face the flat member20on the rounded second ends312of the jig portions310and320. The flat member20pushed out by the adhesive sheet30on the second ends312may be joined to the curved member10with a uniform quality throughout.

The first pressure P1and the second pressure P2may be applied through an additional pressure forming device connected to the jig device300.

The lamination apparatus1000according to an exemplary embodiment may further include an additional device for preventing bubbles or foreign substances from occurring in the process of joining the curved member10to the flat member20. More particularly, when the curved member10and the flat member20are joined first in both ends thereof by both ends of the jig portions310and320, bubbles may occur or foreign substances may be remained in a central part between the both ends. The jig device300of the lamination apparatus1000according to an exemplary embodiment may further include an additional device, which joins central parts of the curved member10and the flat member20first, and then sequentially joins both ends thereof.

FIGS. 15A to 15Care schematic diagrams illustrating a joining process using the jig device300which further includes protruding members810and820according to an exemplary embodiment.

The jig device300according to the illustrated exemplary embodiment may further include the protruding members810and820disposed in at least partial areas of the first jig portion310and the second jig portion320. The protruding members810and820may include a first protruding member810disposed on the first jig portion310, and a second protruding member820disposed on the second jig portion320. The first protruding member810and the second protruding member820may have a shape that is gradually inclined from an area adjacent to the central axis located in the second body portion330, to which the first jig portion310and the second jig portion320are fastened, toward outer ends. For example, the first protruding member810may have a shape, in which a portion adjacent to the first end311of the first jig portion310protrudes upward as compared to a portion adjacent to the second end312. Due to the protruding members810and820, the first jig portion310and the second jig portion320may have shapes, in which central areas adjacent to the second body portion330protrude upward than outer parts. In an exemplary embodiment, the first protruding member810and the second protruding member820may include materials, such as silicone, polyimide, and the like, without being limited thereto.

Referring toFIG. 15A, when the adhesive sheet30is disposed on the first jig portion310and the second jig portion320, and the flat member20is disposed on the adhesive sheet30, central parts thereof may protrude upward and may be gradually inclined toward outer parts according to the first protruding member810and the second protruding member810. The central part protruding upward due to an inclination of the flat member20may be located to be more adjacent to the curved member10than the outer part.

Next, referring toFIGS. 15B and 15C, in the process of applying the second pressure P2, which is relatively high, between the jig device300and the adhesive sheet30, the central parts of the adhesive sheet30and the flat member20may be joined first to the curved member10rather than the outer parts thereof. Afterwards, as the adhesive sheet30is pushed out by the second pressure P2, the central parts and the outer parts of the curved member10and the flat member20may be sequentially joined. Accordingly, in the joining process using the lamination apparatus1000, it is possible to prevent the occurrence of bubbles or foreign substances between the curved member10and the flat member20.

However, the inventive concepts are not limited thereto. In the lamination apparatus1000according to an exemplary embodiment, the jig device300does not include the protruding members810and820, and may include devices which join the curved member10and the flat member20to each other from the central parts thereof first. For example, the jig device300may include a device, which may sequentially apply air pressure from the central part toward the outer part of the adhesive sheet30in the operation of applying the second pressure P2, or may include an additional roller device to sequentially join the curve-shaped member10and the flat member20to each other from the central parts toward the outer parts. In this manner, as shown inFIG. 16, a resultant product, in which the curved member10and the flat member20are joined, may be manufactured by separating the first stage100, the second stage200, and the jig device300from one another.

Through the above processes, the curved member10and the flat member20may be mutually joined using the lamination apparatus1000according to an exemplary embodiment. The lamination apparatus1000includes the jig device300including the pivotable jig portions310and320, so as to prevent damage caused by rubbing between the curved member10and the flat member20. Also, the jig portions310and320may dispose the flat member20by pivoting by a certain radius, such that a gap that may otherwise occur in the curved area of the curved member10or a defect in alignment with the flat member20may be minimized.

More particularly, even when the curved peripheral part of the curved member10has a variety of curvatures, the rounded second ends312of the first jig portion310and the second jig portion320may be designed according to the peripheral part. Accordingly, the lamination apparatus1000according to an exemplary embodiment may join the flat member20with a uniform quality regardless of a shape of the curved member10.

In another exemplary embodiment, when the peripheral part of the curved member10is not curved as compared to the curved member10ofFIG. 8, and the open area of the curved member10is large, the operation of pivoting the first jig portion310and the second jig portion320may be omitted. That is, when it is possible to locate the flat member20to face the curved member10while being spaced apart without bending, the operation of pivoting the jig portions310and320and inserting the flat member20into the open area of the curved member10may be omitted.

FIGS. 17 to 20are cross-sectional views illustrating a joining process using the lamination apparatus according to another exemplary embodiment.

Referring toFIG. 17, a curved-shape member10_1is provided to the accommodation portion120of the first stage100. Unlike the curved member10ofFIG. 8, in the curved member10_1, a width measured in one direction may be equal to a distance between ends of a peripheral part, that is, a width of an open area. Accordingly, the jig device300moves while the jig portions310and320are not pivoted, such that a flat member20_1disposed on the jig device300may be spaced apart from and face the curved member10_1.

Referring toFIG. 18, the jig device300is moved, such that the flat member20_1is spaced apart from and faces the curved-shape member10_1. Unlike the process shown inFIG. 11, the jig portions310and320according to the illustrated exemplary embodiment do not pivot, and thus, the flat member20_1is not bent. Since the open area of the curved member10_1is larger than a width of the flat member20_1which is not bent, the jig device300moves while the flat member20_1is not bent. The flat member20_1may be spaced apart from and face the curved member10_1as the jig device300moves in an upward direction.

Referring toFIGS. 19 and 20, the first stage100and the jig device300are fixed using the second stage200, the first pressure P1is applied between the first stage100and the jig device300, and a second pressure P2_1is applied between the jig device300and the adhesive sheet30. The second pressure P2_1applied to the adhesive sheet30pushes the flat member20_1toward the curved member10_1to mutually join the flat member20_1and the curved member10_1. A description on the above process is substantially the same as the above description with reference toFIGS. 8 to 16. More particularly, as described above with reference toFIGS. 15A to 15C, a process of sequentially joining the flat member20_1and the curved member10_1from central parts thereof to outer parts may be performed.

In an exemplary embodiment, the curved member10and the flat member20, which are mutually joined through the joining process using the lamination apparatus1000, may form a display device. For example, the curved member10may be a cover window10′ (seeFIG. 21), in which at least a partial area thereof is curved, and the flat member20may be a display panel20′ (seeFIG. 21).

FIG. 21is a schematic cross-sectional view of a display device according to an exemplary embodiment.

Referring toFIG. 21, the display device according to the illustrated exemplary embodiment may include the cover window10′, a binding member BP, and the display panel20′. The lamination apparatus1000according to an exemplary embodiment may manufacture the display device by mutually joining the cover window10′ and the display panel20′. More particularly, the display device ofFIG. 21may be a resultant product manufactured through the joining process of the lamination apparatus1000.

The display device displays a screen or an image through a display portion, and may include a variety of devices other than the display portion. For example, the display device1may include a smart phone, a cell phone, a tablet personal computer (PC), a personal digital assistant (PDA), a portable multimedia player (PMP), a television, a game console, a watch type electronic device, a head-mounted display, a monitor of a PC, a laptop computer, a navigation of a vehicle, a dashboard of a vehicle, a digital camera, a camcorder, an outdoor billboard, an electronic display, a variety of medical devices, a variety of detecting devices, a variety of home appliances including a display area (DA), such as a refrigerator, a washing machine, and the like, an Internet of Things (IoT) device, and the like, without being limited thereto. For example, the display device may include a foldable display device, which will be described below, such as a foldable smart phone, a tablet PC, a laptop PC, without being limited thereto.

The cover window10′ of the display device1performs a function of protecting the display panel20′. The cover window10′ may be formed of a transparent material. The cover window10′ may include, for example, glass or plastic.

When the cover window10′ includes glass, the glass may be ultra thin glass (UTG) or thin glass. When the glass is formed as UTG or thin glass, the glass may have a flexible property so as to be warped, bent, folded, or rolled. For example, the cover window10′ may be bent, such that a partial area thereof may have a curved shape, as shown in the drawing.

The display panel20′ of the display device is a panel, which displays a screen or an image, and may include, for example, not only self radiation display panels, such as an organic light emitting display (OLED) panel, an inorganic electroluminescence (EL) display panel, a quantum electrodynamics (QED) panel, a micro light emitting display (LED) panel, a nano-LED panel, a plasma display panel (PDP), a field emission display (FED) panel, a cathode-ray tube (CRT), and the like, but also light-receiving display panels, such as a liquid display panel (LCD), an electrophoretic display (EPD), and the like. Hereinafter, an OLED panel will be described as an example of the display panel20′, and unless particularly noted elsewhere, the OLED panel applied to the exemplary embodiments will be referred as the display panel20′. However, the inventive concepts are not limited to the OLED panel, and other examples of the display panel20′, which are mentioned above or which are well known in the art, may be applied.

The binding member BP is disposed between the cover window10′ and the display panel20′. The binding member BP may mutually bind the cover window10′ and the display panel20′.

In some exemplary embodiments, the display device may further include an optical member between the cover window10′ and the display panel20′. In this case, the optical member may be prepared with the display panel20′ on the providing portion350of the jig device300, and may be joined to the cover window10′ provided on the first stage100, as in the manner described above.

According to an exemplary embodiment, a lamination apparatus includes a first stage, a second stage, and a jig device, and the jig device includes at least one jig portion which is pivotable on a central axis located in a body portion. When the first member and the second member having different shapes are to be joined, the first member is prepared on a first stage and the second member is prepared on the jig device, such that a partial area of the second member may be bent by pivoting the jig portions of the jig device before joining the first member to the second member. Accordingly, the lamination apparatus may easily join the first member to the second member even when they have different shapes.

Also, according to an exemplary embodiment, a display device can be manufactured by joining a cover window having a curved surface shape to the display panel having a flat surface shape at precise positions using the lamination apparatus without a gap therebetween, while preventing or at least suppressing damage to a display panel or defects from the joining process.