Flexible display panel peeling apparatus and peeling method using the same

A flexible display panel peeling apparatus for peeling a flexible display panel attached to a top surface of a substrate includes a stage fixed to the substrate and a peeling plate comprising a bottom surface that is convex toward the flexible display panel and a plurality of adsorption units defined in the bottom surface to adsorb the flexible display panel to the bottom surface. Since the flexible display panel is successively peeled through the peeling plate, the flexible display panel may be peeled from the substrate without being damaged.

CROSS REFERENCE TO RELATED APPLICATION

This U.S. non-provisional patent application claims priority from and the benefit of Korean Patent Application No. 10-2013-0132315, filed on Nov. 1, 2013, which is hereby incorporated by reference for all purposes as if fully set forth herein.

BACKGROUND

Exemplary embodiments of the present disclosure relate to a flexible display panel peeling apparatus having improved reliability in a flexible display panel peeling process and a flexible display panel peeling method using the same.

Electronic equipment, such as smart phones, digital cameras, notebook computers, navigation units, smart televisions, and the like, include a display panel for displaying images.

In recent years, flexible display panels are being developed for use in the electronic equipment. Since components of the flexible display panel are formed of a flexible material, the flexible display panel may have a flexible property.

A flexible display panel may include pixels for generating images. To form the pixels, the flexible display panel may be attached to a substrate that is formed of a rigid material, and then, patterning and deposition processes may be performed on the substrate. When the pixel formation is finished, a peeling process for peeling the flexible display panel from the substrate may be performed. However, there is a need for an improved peeling process that may reduce or eliminate damage to the flexible display panel during the peeling process.

The above information disclosed in this Background section is provided to enhance understanding of the background of the disclosed subject matter and therefore may contain information that does not form any part of the prior art nor what the prior art may suggest to a person of ordinary skill in the art.

SUMMARY

Exemplary embodiments of the present disclosure provide a flexible display panel peeling apparatus having improved reliability in a flexible display panel peeling process and a flexible display panel peeling method using the same.

Exemplary embodiments of the present disclosure provide a flexible display panel peeling method. The method includes disposing a flexible display panel on a substrate and disposing a peeling plate on the flexible display panel. The peeling plate includes adsorption units and a convex bottom surface configured to contact the flexible display panel. The method further includes adsorbing, via the adsorption units, the flexible display panel, and rolling the peeling plate on the flexible display panel.

Exemplary embodiments of the present disclosure provide a flexible display panel peeling apparatus including a substrate configured to support a flexible display panel and a peeling plate. The peeling plate includes adsorption units and a convex bottom surface configured to contact the flexible display panel. The peeling plate is configured to be rolled on the flexible display panel.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

Exemplary embodiments of the disclosed subject matter are described more fully hereinafter with reference to the accompanying drawings. The disclosed subject matter may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. Rather, the exemplary embodiments are provided so that this disclosure is thorough and complete, and will convey the scope of the disclosed subject matter to those skilled in the art. In the drawings, the size and relative sizes of layers and regions may be exaggerated for clarity. Like reference numerals in the drawings denote like elements.

It will be understood that when an element or layer is referred to as being “on”, “connected to”, or “coupled to” another element or layer, it can be directly on, connected, or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on”, “directly connected to”, or “directly coupled to” another element or layer, there are no intervening elements or layers present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. It may also be understood that for the purposes of this disclosure, “at least one of X, Y, and Z” can be construed as X only, Y only, Z only, or any combination of two or more items X, Y, and Z (e.g., XYZ, XYY, YZ, ZZ).

Exemplary embodiments of the disclosed subject matter are described herein with reference to cross-section illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of the disclosed subject matter. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, exemplary embodiments of the disclosed subject matter should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.

Hereinafter, exemplary embodiments of the disclosed subject matter will be described in detail with reference to the accompanying drawings.

FIG. 1is a perspective view of a flexible display panel peeling apparatus according to exemplary embodiments of the prevent disclosure.FIG. 2is a perspective view of the flexible display panel ofFIG. 1.FIG. 3is a bottom surface of the peeling plate illustrated inFIG. 1, andFIG. 4is a cross-sectional view of the flexible display panel peeling apparatus illustrated inFIG. 1.

Referring toFIGS. 1, 2, 3, and 4, a flexible display panel peeling apparatus1000may include a peeling plate100and a stage200. A flexible display panel300may be peeled from a substrate400attached to the stage200.

The flexible display panel300extends by a first length L1 in a first direction D1 and by a second length L2 in a second direction D2 perpendicular to the first direction D1. In some cases, the first length L1 may be greater than the second length L2. The flexible display panel300may have a substantially rectangular shape. However, it should be understood that the flexible display panel300may have various shapes.

The flexible display panel300may be flexible. Each of the components of the flexible display panel300may be formed of a flexible material, such as plastic, thus providing the flexible display panel300with a flexible property. As shown inFIG. 2, the flexible display panel300may be bent in a third direction D3 perpendicular to the first and second directions D1 and D2 by application of an external force.

Hereinafter, a direction opposite to the first direction D1 may be referred to as a fourth direction D4, a direction opposite to the second direction D2 may be referred to as a fifth direction D5, and a direction opposite to the third direction D3 may be referred to as a sixth direction D6.

The flexible display panel300is configured to display images. The flexible display panel300may include various display panels, such as an organic light emitting display panel, a liquid crystal display panel, a plasma display panel, an electrophoretic display panel, and an electrowetting display panel.

The flexible display panel300includes a pixel310for generating images and a plurality of signal lines321,322,323, and324. The plurality of signal lines321,322,323, and324include first gate line321and second gate line322for receiving gate signals and first data line323and second data line324for receiving data voltages. The first gate line321and second gate line322extend in the first direction D1 and are arranged in parallel with each other in the second direction D2. The first data line323and second data line324extend in the second direction D2 and are arranged in parallel with each other in the first direction D1.

The pixel310may be connected to a corresponding gate line of the first gate line321and the second gate line322and a corresponding data line of the first data line323and the second data line324to generate an image.

The substrate400may be formed of various suitable materials, including, for example, a rigid material such as glass. The substrate400includes a substrate top surface410facing the sixth direction and a substrate bottom surface420opposite to the substrate top surface410. The substrate400may have a shape (e.g., rectangular) corresponding to the shape of the flexible display panel300. When viewed in plan view, the substrate400may have a size greater than a size of the flexible display panel300.

The flexible display panel300may be attached to the substrate top surface410. The pixel310and the plurality of signal lines321,322,323, and324may be formed on the flexible display panel300through various suitable processes, such as pixel and line formation processes. Since the flexible display panel300is flexible, the pixel310and the plurality of signal lines321,322,323, and324may be bent or stretched while performing the pixel and line formation processes to cause a misalignment therebetween. Accordingly, the pixel310and the signal lines321,322,323, and324may be misaligned with respect to each other. To prevent the misalignment from occurring, the pixel and line formation processes may be performed while the flexible display panel300is attached to the substrate400. For example, the flexible display panel300and the substrate400may be attached to each other by using an adhesive layer (not shown) that is disposed between the flexible display panel300and the substrate400.

The stage200fixes the substrate400and includes a base plate210and an adsorption pad220. The adsorption pad220is disposed on a top surface of the base plate210to fix the substrate400to the base plate210.

Each of the base plate210and the adsorption pad220may have a shape (e.g., rectangular) corresponding to the shapes of the flexible display panel300and the substrate400.

The adsorption pad220includes a seating area221. The substrate400is seated on the seating area221. The substrate bottom surface420contacts the seating area221.

In some cases, the adsorption pad220includes a plurality of vacuum holes222in the seating area221. The adsorption pad220may adsorb the substrate400using a vacuum provided by the vacuum holes222. The plurality of vacuum holes222may have various suitable shapes, such as an approximate matrix shape. The plurality of vacuum holes222are defined by partially opening a top surface of the adsorption pad220in the third direction D3. When viewed in plan view, each of the vacuum holes222may have a bar shape that extends in the second direction D2. However, it should be understood that the vacuum holes222may be modified in various shapes.

The adsorption pad220includes a vacuum cavity223. The vacuum cavity223may be a hollow within the adsorption pad220. The vacuum cavity223may have an approximate rectangular parallelepiped shape that extends to correspond to the seating area221. The vacuum cavity223may be formed under the plurality of vacuum holes222. The plurality of vacuum holes222may extend in the third direction D3 and may be connected to the vacuum cavity223. The adsorption pad220includes a vacuum exhaust tube224formed by opening one side surface of the adsorption pad220. The vacuum exhaust tube224extends in the first direction D1 to connect the vacuum cavity223to a first vacuum unit (not shown). The first vacuum unit is configured to vacuum-exhaust the vacuum cavity223and the plurality of vacuum holes222.

The plurality of vacuum holes222may be vacuum-exhausted to be in a negative pressure state. Thus, the substrate400may be vacuum-adsorbed to the adsorption pad220by a suction force generated in the plurality of vacuum holes222.

The peeling plate100may be disposed on the stage200, and the flexible display panel300and the substrate400may be disposed between the peeling plate100and the stage200.

The peeling plate100includes a top surface110, a bottom surface120, a side surface130, and a plurality of adsorption units140. The peeling plate100adsorbs the flexible display panel300to the bottom surface120to successively peel the flexible display panel300from the substrate400.

The top surface110faces the sixth direction D6, and the bottom surface120faces the third direction D3. The side surface130may face the fifth direction D5 and may be formed between the top surface110and the bottom surface120to connect the top surface110to the bottom surface120in the first direction D1.

The top surface110may have a substantially flat shape. When viewed in a plan view, the top surface110may have a substantially rectangular shape corresponding to a shape of the flexible display panel300. The top surface110may have a third length L3 extending in the first direction D1 and a fourth length L4 extending in the second direction D2. In some cases, the fourth length L4 may be greater than the second length L2 of the flexible display panel300.

A section of the peeling plate100in the second direction D2 may have, for example, a “D” shape that rotates at an angle of about 90 degrees in a clockwise direction. Thus, the bottom surface120may have a curved surface that is convex toward the flexible display panel300. The bottom surface120may include a first end121and a second end122. The first end121may be disposed on a side of the bottom surface120in the fourth direction D4 to extend in the second direction D2 so that the first end121is connected to the top surface110along the second direction D2. The second end122may be disposed on a side of the bottom surface120in the first direction D1 to extend in the second direction D2 so that the second end122is connected to the top surface110along the second direction D2.

Each of the first end121and the second end122extends by the fourth length L4 in the second direction D2. An outer circumferential surface of the bottom surface120may have a length L5 greater than the first length L1 of the flexible display panel300.

The adsorption units140adsorb the flexible display panel300. The bottom surface120includes an adsorption area123. In some cases, the plurality of adsorption units140may be formed in the adsorption area123in an approximate matrix shape. When viewed in a plan view, the adsorption area123may have an approximate rectangular shape corresponding to the shape of the flexible display panel300. The flexible display panel300may include a panel top surface320facing the sixth direction D6, and the plurality of adsorption units140may adsorb the panel top surface320of the flexible display panel300.

The plurality of adsorption units140include an adsorption pipe141, an upper hole142, and a lower hole143to adsorb the flexible display panel300. The adsorption pipe141is formed by opening the top surface110up to the bottom surface120along the third direction D3. The upper hole142is formed at the top surface110of the peeling plate100at one end of an adsorption pipe141, and the lower hole143is formed at the bottom surface120of the peeling plate100at another end of the adsorption pipe141.

When viewed in a plan view, the adsorption pipe141, the upper hole142, and the lower hole143may have a circular shape. However, it should be understood that the adsorption pipe141, the upper hole142, and the lower hole143may have various shapes and are not limited to circular shapes.

The upper hole142may be connected to a second vacuum unit (not shown). The second vacuum unit may vacuum-exhaust the inside of the adsorption pipe141to provide a negative pressure state inside the adsorption pipe141.

The lower hole143may contact the panel top surface320of the flexible display panel300when the panel top surface320contacts the bottom surface120. In this case, the panel top surface320of the flexible display panel300may be vacuum-adsorbed to the bottom surface120by the suction force generated in the lower hole143.

The flexible display panel peeling apparatus1000may further include a moving unit (not shown) for moving the peeling plate100. The moving unit may move the peeling plate100to peel the flexible display panel300.

FIGS. 5A and 5Billustrate examples of a peeling process according to exemplary embodiments of the present disclosure.FIG. 6is an enlarged cross-sectional view of a region MA ofFIG. 5A.

Referring toFIG. 5A, the flexible display panel300may be adsorbed to the bottom surface120of the peeling plate100to successively peel the flexible display panel300from the substrate400.

The flexible display panel300includes a first panel end and a second panel end340. The first panel end330is disposed on a side of the flexible display panel300in the fourth direction D4 to extend in the second direction D2 (as shown inFIG. 1), and the second panel end340is disposed on a side opposite to the first panel end330in the first direction D1 to extend in the second direction D2.

The peeling plate100may be disposed on the flexible display panel300in the third direction D3 in an inclined-rolling manner, as shown inFIGS. 5A and 5B. Thus, the first end121may contact the first panel end330. An adsorption unit of the plurality of adsorption units140adjacent to the first end121may vacuum-adsorb the panel top surface320of the first panel end330.

Thereafter, the peeling plate100may roll along the flexible display panel300in the first direction D1 so that the bottom surface120successively contacts the panel top surface320along the first direction D1. The plurality of adsorption units140may then successively adsorb the panel top surface320in contact with the bottom surface120.

The flexible display panel300adsorbed to the peeling plate100, as shown inFIG. 5A, may subsequently be peeled from the substrate400by the peeling plate100. Referring toFIG. 5B, the flexible display panel300may be successively peeled from the substrate400along the curved surface of the bottom surface120of the peeling plate100. The peeling may successively proceed from the first panel end330to the second panel end340in the first direction D1. Since the flexible display panel300has flexibility, the flexible display panel300may be adsorbed and peeled in a curved manner to corresponding to the curved surface of the bottom surface120.

The peeling plate100may roll along the panel top surface320until the second end122contacts the second panel end340. As described above, the outer circumferential surface of the bottom surface120has the length L5 greater than the first length L1 of the flexible display panel300. Thus, when the peeling plate100fully rolls up to the second end122, the bottom surface120successively contacts the entire panel top surface320. Thus, the flexible display panel300is fully peeled from the substrate400along the first direction D1.

As described above, when the flexible display panel300is successively peeled through the peeling plate100, the flexible display panel300may be peeled from the substrate400without damaging the flexible display panel300. Thus, the flexible display panel peeling apparatus1000may prevent the flexible display panel300from being damaged during the peeling process to improve reliability in the peeling process.

Referring toFIG. 6, a peeling region350of the flexible display panel300that is peeled from the substrate400is determined at a specific time point at which the peeling plate100rolls along the first direction D1. The peeling region350ascends in the sixth direction D6 as the peeling plate100rolls.

As described above, since the flexible display panel300is attached to the substrate400by the adhesive layer, if the peeling region350ascends, a tension may be applied to a bottom surface of the peeling region350toward the substrate400by the adhesive layer. The tension may be generated to correspond to a size of the peeling region350. For example, if the peeling region350is wide, the tension applied to the peeling region350is correspondingly large in intensity. If the peeling region350is narrow, the tension applied to the peeling region350is correspondingly small in intensity.

Since the flexible display panel300is successively peeled in a curved manner in the first direction D1 along the curved surface of the bottom surface120, the peeling region350may be narrow in the first direction D1. Thus, the tension applied to the peeling region350may be small in intensity. As a result, the flexible display panel300may be easily peeled from the substrate400, and also, the flexible display panel300may not be damaged thereby improving reliability in the peeling process.

If a curvature radius of the bottom surface120is increased, the flexible display panel300may be more easily peeled. If the peeling plate100has a roller shape, a size of the peeling plate100will increase as the curvature radius of the roller shape increases. However, according to exemplary embodiments of the present disclosure, the bottom surface120may have a curved surface having a curvature radius, whereas the top surface110may be flat. Thus, the peeling plate100may be reduced in size.

FIGS. 7A, 7B, and 7Cillustrate a flexible display panel peeling apparatus2000with a peeling knife500according to exemplary embodiments of the present disclosure. The flexible display panel peeling apparatus2000includes the peeling plate100and the stage200described with reference toFIGS. 1, 2, 3, 4, 5, and 6.

Referring toFIGS. 7A, 7B, and 7C, the flexible display panel peeling apparatus2000includes a peeling knife500. The peeling knife500may peel one end of the flexible display panel300from the substrate400in any suitable direction, for example, the second direction D2, to initially peel the flexible display panel300.

The peeling knife500may be disposed adjacent to the first panel end330. The peeling knife500includes a first surface510facing, in an inclined manner, the first panel end330, a second surface520opposite to the first surface510and facing, in an inclined manner, a top surface of the substrate400, a side surface530connecting the first and second surfaces510and520to each other, and an insertion edge540. Each of the first surface510and the second surface520extends in an inclined manner in the first direction D1 to form the insertion edge540so that the peeling knife500is easily inserted between the first panel end330and the substrate400.

The insertion edge540may be inserted into a side of the first panel end330in the fifth direction D5. Thereafter, when the insertion edge540is inserted between the first panel end330and the substrate400, the peeling knife500may move along the second direction D2. Thus, the insertion edge540may peel the first panel end330from the substrate400in the second direction D2.

Thereafter, the peeling plate100may vacuum-adsorb a side of the first panel end330that is initially peeled.

The peeling plate100may roll along the flexible display panel300in the first direction D1 so that the bottom surface120successively contacts the panel top surface320along the first direction D1. Thus, the bottom surface120successively contacts the panel top surface320of the flexible display panel300, and the plurality of adsorption units140successively adsorb the panel top surface320that is in contact with the bottom surface120.

The flexible display panel300adsorbed to the peeling plate100is successively peeled from the substrate400in the first direction D1 by the peeling plate100.

In summary, to easily peel the flexible display panel300from the substrate400, an initial peeling process may be performed using the peeling knife500and subsequently the peeling process may be performed using a peeling plate100. The flexible display panel300may be initially peeled without applying a large force to the flexible display panel300, and also, the initial peeling may be more accurately performed. Thus, the peeling process may be performed without damaging the flexible display panel300to improve reliability in the peeling process.

FIGS. 8A, 8B, 8C, and 8Dillustrate a flexible display panel peeling apparatus3000with a scribing unit610and a substrate inverting unit620according to exemplary embodiments of the present disclosure. The flexible display panel peeling apparatus3000according to exemplary embodiments of the disclosure includes the peeling plate100and the stage200described with reference toFIGS. 1, 2, 3, 4, 5, and 6, although the peeling plate100and the stage200have not been shown in8A,8B,8C, and8D.

Referring toFIGS. 8A, 8B, 8C, and 8D, the flexible display panel peeling apparatus3000may include a scribing unit610and a substrate inverting unit620.

The substrate inverting unit620is configured to invert the flexible display panel300and the substrate400, and to support the flexible display panel300and the substrate400after inverting the flexible display panel300and the substrate400.

The substrate400may be divided into a first region430adjacent to the first panel end330and a second region440that is a region other than the first region430. The first region430and the second region440bisect the substrate400in the second direction D2.

The substrate400may include a first substrate end450and a second substrate end460. The first substrate end450extends from a side of the first region430in the fourth direction D4 and extends further than the first panel end330. A surface of the first substrate end450may be exposed. The second substrate end460extends from a side of the second region440in the first direction D1 and extends further than the second panel end340. A surface of the second substrate end460may be exposed.

The substrate inverting unit620includes a first support621and a second support622. The first support621may be disposed on a side of the first substrate end450and may extend in the second direction D2. The first support621may be coupled to the first substrate end450. The second support622may be disposed on a side of the second substrate end460and may extend in the second direction D2. The second support622may be coupled to the second substrate end460. In an initial state, the panel top surface320may face the sixth direction D6. The first support621and the second support622may then invert the flexible display panel300and the substrate400so that the substrate bottom surface420faces the sixth direction D6. The scribing unit610is configured to scribe the substrate bottom surface420while moving in the fifth direction D5 along a boundary between the first region430and the second region440.

Thereafter, the first support621and the second support622re-invert the flexible display panel300and the substrate400so that the panel top surface320faces the sixth direction D6 again. Since the first region430and the second region440are separated from the flexible display panel300along the boundary between the first region430and the second region440which are scribed, the first panel end330may be initially peeled from the substrate400.

Thereafter, the substrate400and the flexible display panel300from which the first region430is removed are fixed to the stage200. Then, the peeling plate100vacuum-adsorbs a side of the first panel end330that is initially peeled.

Thereafter, the peeling plate100may roll along the flexible display panel300in the first direction D1 so that the bottom surface120successively contacts the panel top surface320along the first direction D1. Thus, the bottom surface120successively contacts the panel top surface320of the flexible display panel300, and the plurality of adsorption units140successively adsorb the panel top surface320that is in contact with the bottom surface120.

The flexible display panel300adsorbed to the peeling plate100is successively peeled from the substrate400in the first direction D1 by the peeling plate100.

In summary, to easily peel the flexible display panel300from the substrate400, an initial peeling process may be performed using a scribing unit610and a substrate inverting unit620and subsequently the peeling process may be performed using a peeling plate100. The flexible display panel300may be initially peeled without applying large force to the flexible display panel300, and also, the initial peeling may be more accurately performed. Thus, the peeling process may be performed without damaging the flexible display panel300to improve reliability in the peeling process.

According to exemplary embodiments of the disclosure, a flexible display panel peeling apparatus may successively peel a flexible display panel along a curved bottom surface of a peeling plate. Thus, the flexible display panel may be peeled from the substrate without damaging the flexible display panel. Thus, the flexible display panel peeling process using the flexible display panel peeling apparatus may be improved in reliability.

It should be understood that the peeling process has been described with respect to certain directions in the present disclosure. However, exemplary embodiments of the present disclosure are not limited thereto. For example, the peeling process may be performed in other directions other than direction D1. Similar variations may be made without departing from the scope of the disclosed subject matter.