Display device with flexible substrate and manufacturing method thereof

A display device and a manufacturing method thereof are provided. The display of the present invention includes a flexible substrate, a display layer, a protecting layer, an electronic unit, and a filling glue. The flexible substrate has a carrying surface. The display layer is disposed on the carrying surface and has a side edge. The protecting layer is disposed on the opposite side of the display layer corresponding to the carrying surface. The electronic unit is disposed on the carrying surface with a space formed between the electronic unit and the side edge of the display layer. The filling glue is filled in the space and connected with the side edge of the display layer, the electronic unit, and the carrying surface.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to a display device and a manufacturing method thereof. More particularly, this invention relates to a display device with a flexible substrate and a manufacturing method thereof.

2. Description of the Prior Art

With the progress of manufacturing technique, various display devices are provided. Considering the requirement of being light, thin, short, small, and portable, the next generation display devices tend to be rollable and easily to carry, thus the flexible display devices are very common. Generally speaking, flexible display devices are soft and rollable, hence could be rolled up or folded for storage or transportation when not in use. Moreover, flexible display devices could be easily disposed on a non-planar surface to provide different visual experiences.

As the prior art shown inFIG. 1A, a conventional flexible display device80includes a flexible substrate10, a display layer30, a protecting layer50, and an electronic unit70. The flexible substrate10has a carrying surface11. The display layer30is disposed on the carrying surface11. The protecting layer50is disposed on the opposite side of the display layer30with respect to the carrying surface11. The electronic unit70is disposed on the carrying surface11. In the manufacturing process, the flexible display device80is usually carried by a glass substrate20and is de-bonded after the process is complete.

As shown inFIGS. 1B and 1C, because the flexible substrate is flexible and a space40exists between the display layer30and the electronic unit70, over-bending of the flexible substrate10in local area due to its insufficient strength may occur when de-bonding the flexible display device80from the glass substrate20. The local area could be, for example but not limited to, the boundary between the flexible substrate10and the side of the electronic unit70that faces the display layer30as shown inFIG. 1B, and the boundary between the display layer30and the flexible substrate10as shown inFIG. 1C. Thus, the conventional flexible display device80breaks down easily in the manufacturing process. The conventional flexible display device80and the manufacturing method thereof are still improvable.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a display device not easily breaking down during the manufacturing process.

It is an object of the present invention to provide a display device manufacturing method for reducing the breaking down of the display device in the manufacturing process.

The display device of the present invention includes a flexible substrate, a display layer, a protecting layer, an electronic unit, and a filling glue. The flexible substrate has a carrying surface. The display layer is disposed on the carrying surface, wherein the display layer has a side edge. The protecting layer is disposed on the opposite side of the display layer corresponding to the carrying surface. The electronic unit is disposed on the carrying surface, wherein the electronic unit forms a space with the side edge of the display layer. The filling glue is filled in the space and connected with the side edge of the display layer, the electronic unit, and the carrying surface.

The Young's modulus of the filling glue and the Young's modulus of the display layer are substantially the same or less than 15% in the difference between the two. The Young's modulus of the filling glue could be between the Young's modulus of the display layer and the Young's modulus of the flexible substrate.

The protecting layer has an end edge not exceeding the side edge of the display layer, wherein the filling glue covers a portion of the protecting layer. The filling glue covers a portion of the electronic unit. The filling glue surrounds the electronic unit. The flexible substrate has a circuit formed on the carrying surface, wherein the circuit is coupled to the circuit, wherein the circuit within the space is covered by the filling glue. The display device further comprises a circuit board coupled to the circuit, wherein the electronic unit is disposed between the circuit board and the side edge of the display layer, wherein the filling glue is filled between the electronic unit and the circuit board. The filling glue covers a portion of the circuit board.

The protecting layer has an end edge protruding over the side edge of the display layer, the portion of the end edge of the protecting layer protruding over the side edge of the display layer forms an interlayer channel with the carrying surface along the extending direction of the side edge of the display layer, a portion of the filling glue is contained in the interlayer channel. The ratio between the length of the portion of the end edge of the protecting layer protruding over the side edge of the display layer and the thickness of the display layer is between 9.31 and 12.42. The display device further comprises a first isolating glue strip at least partially disposed along one side of the interlayer channel, wherein the isolating glue strip connects the portion of the end edge of the protecting layer extending out of the side edge of the display layer with the carrying surface to isolate the filling glue within the interlayer channel from the filling glue out of the interlayer channel.

The display device further comprises a second isolating glue strip surrounding the electronic unit, wherein one end of the first isolating glue strip closer to the electronic unit extends to connect with the second isolating glue strip. The side edge of the display layer includes two protruding parts disposed apart and symmetrically, wherein the electronic unit is disposed between the protruding parts, wherein the interlayer channel and the first isolating glue strip are disposed along the sides of the protruding parts facing the electronic unit. The display device further comprises a third isolating glue strip disposed on the carrying surface, wherein the two opposite ends of the third isolating glue strip respectively connect to the first isolating glue strip extending from the side of the two protruding parts to enclose an area.

The display layer includes two protruding parts disposed apart and symmetrically, wherein the electronic unit is disposed between the protruding parts, wherein the interlayer channel is disposed along the sides of the protruding parts facing the electronic unit and is broke off at the end of the protruding parts. The display device further comprises a third isolating glue strip disposed on the carrying surface, wherein the two opposite ends of the third isolating glue strip respectively connect to the places that the interlayer channel extending along the sides of the two protruding parts breaks off to enclose an area.

The display layer includes two protruding parts disposed apart and symmetrically, wherein the electronic unit is disposed between the protruding parts, wherein the interlayer channel is disposed along the sides of the protruding parts facing the electronic unit and is broke off at the end of the protruding parts.

The protecting layer does not cover the side edge of the display layer, and the filling glue covers a portion of a top surface of the display layer that is uncovered by the protecting layer. The ratio between the length of the portion of the side edge of the display layer extending out of the end edge of the protecting layer to the thickness of the display layer is between 18.63 and 31.05.

The filling glue includes a glue body and a film. The glue body is filled in the space and connected with the side edge of the display layer, the electronic unit, and the carrying surface, wherein the glue body is capable of absorbing energy to transform from liquid state to solid state. The film covers and adheres to a portion of the protecting layer and the glue body.

The display device manufacturing method, comprising: forming a cutting line on a carrying surface of a flexible substrate; disposing a display layer on the carrying surface, wherein the display layer has a side edge; forming a protecting layer on the opposite side of the display layer corresponding to the carrying surface, wherein the protecting layer has an end edge; disposing an electronic unit on the carrying surface to form a space with the display layer, wherein the electronic unit and the display layer are disposed at the same side of the cutting line; filling a filling glue in the space, wherein the filling glue is connected with the side edge of the display layer, the electronic unit, and the carrying surface; and taking a portion of the flexible substrate carrying the display layer and the electronic unit out form the cutting line.

The step of forming the protecting layer includes making the end edge of the protecting layer not exceed the side edge of the display layer, wherein the step of filling the filling glue includes making the filling glue partially overflow the space and covers the protecting layer. The step of filling the filling glue includes making the filling glue partially overflow the space and covers the electronic unit. The step of filling the filling glue includes making the filling glue surround the electronic unit. The step of forming the protecting layer includes making the end edge of the protecting layer extend out of the side edge of the display layer, wherein the portion of the end edge of the protecting layer extending out of the side edge of the display layer forms an interlayer channel with the carrying surface along the extending direction of the side edge of the display layer, wherein the step of filling the filling glue includes making the filling glue contained in the interlayer channel.

The method further comprises disposing a first isolating glue strip at least partially along one side of the interlayer channel, wherein the isolating glue strip connects the portion of the end edge of the protecting layer extending out of the side edge of the display layer with the carrying surface to isolate the filling glue within the interlayer channel from the filling glue out of the interlayer channel, wherein the viscosity of the first isolating glue strip before hardening is greater than the viscosity of the filling glue before hardening. The step of filling the filling glue includes determining the filling amount of the filling glue to control the amount of the filling glue filled into the interlayer channel. The method further comprises disposing a second isolating glue strip surrounding the electronic unit, wherein one end of the first isolating glue strip closer to the electronic unit extends to connect with the second isolating glue strip, wherein the viscosity of the second isolating glue strip before hardening is greater than the viscosity of the filling glue before hardening.

The side edge of the display layer includes two protruding parts disposed apart and symmetrically, wherein the electronic unit is disposed between the protruding parts, wherein the interlayer channel and the first isolating glue strip are disposed along the sides of the protruding parts facing the electronic unit, wherein the method further comprising disposing a third isolating glue strip on the carrying surface, wherein the two opposite ends of the third isolating glue strip respectively connect to the first isolating glue strip extending from the side of the two protruding parts to enclose an area, wherein the viscosity of the third isolating glue strip before hardening is greater than the viscosity of the filling glue before hardening.

The step of forming the protecting layer includes: making one end of the interlayer channel extend toward the cutting line; and cutting the protecting layer and the display layer to even at or close to the intersection of the interlayer channel and the cutting line to break off the interlayer channel. The side edge of the display layer includes two protruding parts disposed apart and symmetrically, the electronic unit is disposed between the protruding parts, the interlayer channel is disposed along the sides of the protruding parts facing the electronic unit and is broke off at the bottom end of the protruding parts, wherein the method further comprising disposing a third isolating glue strip on the carrying surface, wherein the two opposite ends of the third isolating glue strip respectively connect to the places that the interlayer channel extending along the sides of the two protruding parts breaks off to enclose an area, the viscosity of the third isolating glue strip before hardening is greater than the viscosity of the filling glue before hardening.

The step of forming the protecting layer includes: making one end of the interlayer channel extend toward the cutting line; and forming an opening on the protecting layer at or close to the intersection of the interlayer channel and the cutting line to break off the interlayer channel.

The step of forming the protecting layer includes making the end edge of the protecting layer shrink from the side edge of the display layer, wherein the step of filling the filling glue includes making the filling glue cover the display layer. The step of filling the filling glue includes: filling a glue body in the space and connecting with the side edge of the display layer, the electronic unit, and the carrying surface; applying energy onto the glue body to transform the glue body from liquid state to solid state; and covering and adhering a film to a portion of the protecting layer and the glue body.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention provides a display device and a manufacturing method thereof, wherein the display device is a flexible display using a flexible substrate. More particularly, the flexible substrate is made of materials such as tin, 430 stainless steel, or polyimide (PI). The flexible display is a display device having flexibility such as OLED display or electronic paper.

As a preferred embodiment shown inFIG. 2A, a display device800of the present invention includes a flexible substrate100, a display layer300, a protecting layer500, an electronic unit700, and a filling glue900. The flexible substrate100has a carrying surface110. The display layer300is disposed on the carrying surface110, and the display layer300has a side edge310. The protecting layer500is disposed on the opposite side of the display layer300with respect to the carrying surface110. The electronic unit700is disposed on the carrying surface110adjacent to the side edge310of the display layer300, wherein a space400is formed between the electronic unit700and the side edge310of the display layer300. The filling glue900is filled in the space400and contacted with the side edge310of the display layer300, the electronic unit700, and the carrying surface110. In other words, the side edge310of the display layer300, the carrying surface110, and one side of the electronic unit700respectively form three faces of the space400, wherein the filling glue900filled in the space400is contacted with the three faces. The filling glue900is a glue body capable of absorbing energy to transform from liquid state to solid state. In other words, the filling glue900is a liquid that can be solidified by methods such as UV light illuminating or heating. More particularly, in the manufacturing process, the filling glue900is filled into the space400in liquid state and then solidified. During the manufacturing process, as shown inFIG. 2B, the display device800is preferably disposed on a carrying substrate200. When the carrying substrate is a light-transmittable substrate such as a glass substrate, light is able to transmit through the carrying substrate200to solidify the filling glue900.

Since the space400between the display layer300and the electronic unit700is filled with the filling glue900, over-bending of the flexible substrate100in local area due to its insufficient strength can be prevented when the flexible display device800is de-bonded from the carrying substrate200, which can be made of glass or aluminum, for example. The local area could be, for example but not limited to, the boundary between the side edge310of the display layer300and the flexible substrate100, and the boundary between the flexible substrate100and the side of the electronic unit700that faces the side edge310of the display layer300. Thus, the breaking down of the display device800in the manufacturing process can be reduced.

The Young's modulus of the filling glue900and the Young's modulus of the display layer300are substantially the same or have a difference less than 15% therebetween, or the Young's modulus of the filling glue900could be between the Young's modulus of the display layer300and the Young's modulus of the flexible substrate100.

More specifically, the filling glue900is preferably an object having a certain elasticity, hence the display layer300and the protecting layer500can shift toward the space400to a limited extent. In other words, the display device800can bend to a limited extent, without losing flexibility due to the disposition of the filling glue900in the space400. On the other hand, by connecting with the side edge310of the display layer300, the electronic unit700, and the carrying surface110, the position of the filling glue900with respect to the side edge310of the display layer300, the electronic unit700, and the carrying surface110can be maintained. As such, the flexible substrate100can further form a continuous unity with the display layer300, the electronic unit700, and the filling glue900by such a connection relationship among them.

As the preferred embodiment shown inFIG. 2A, the protecting layer500has an end edge510not exceeding the side edge310of the display layer300, and the filling glue900covers a portion of the top surface of the protecting layer500. More particularly, in the preferred embodiment, the end edge510of the protecting layer500is flush with the side edge310of the display layer300, and the filling glue900covers the end edge510of the protecting layer500that is close to the electronic unit700, i.e. covers the top of the side edge310of the display layer300. By contacting the filling glue900with the top surface of the protecting layer500, the strength of the unity structure can be further enhanced. Similarly, the filling glue900preferably covers a portion of the top surface of the electronic unit700to reduce the bending of the flexible substrate100. In other embodiments, however, in order to decrease the material cost of the filling glue900or to control the filling amount of the filling glue900, the filling glue900can be filled in the space400only, instead of covering the top surface of the protecting layer500and/or the electronic unit700.

As the preferred embodiment shown inFIG. 4, the filling glue900surrounds the electronic unit700. A circuit140is formed on the carrying surface110for coupling the display layer300to the electronic unit700. The circuit140within the space400(shown inFIG. 2) is covered by the filling glue900to decrease the possibility of oxidization or damage of the circuit140caused by contacting with oxygen, moisture, or other materials. As the preferred embodiment shown inFIGS. 2B and 4, the display device800further includes a circuit board600coupled to the circuit140(shown inFIG. 4), wherein the electronic unit700is disposed between the circuit board600and the side edge310of the display layer300(shown inFIG. 2B). Similarly, the filling glue900is filled between the electronic unit700and the circuit board600to decrease the possibility of oxidization or damage of the circuit140caused by contacting with oxygen, moisture, or other materials. The filling glue900covers a portion of the top surface of the circuit board600to decrease the bending of the flexible substrate100.

In a different embodiment, the position of the end edge510of the protecting layer500with respect to the side edge310of the display layer300can differ in accordance with different design requirements. As shown inFIG. 5, the protecting layer500includes an end edge510of the protecting layer500protruding over the side edge310of the display layer300. The portion of the protecting layer500that protrudes over the side edge310of the display layer300forms an interlayer channel320with the carrying surface110along the extending direction of the side edge310of the display layer300, wherein a portion of the filling glue900is contained in the interlayer channel320. More particularly, the side edge310of the display layer300, a bottom side511of the protecting layer500that protrudes over the of the display layer300, and the carrying surface110of the flexible substrate100respectively form three faces of the interlayer channel320. In the manufacturing process, when liquid filling glue900contacts a portion of the interlayer channel320, it flows to the other portions of the interlayer channel320due to capillary attraction. The ratio of the length L1of the portion of the protecting layer500that protrudes over the side edge310of the display layer300to the thickness T of the display layer300is preferably between 9.31 and 12.42 to obtain better capillary attraction.

As the top view of the embodiment shown inFIG. 6Aand the corresponding P-P′ cross-sectional view shown inFIG. 6B, the end edge510of the protecting layer500protrudes over the side edge310of the display layer300, and the display device800further includes a first isolating glue strip910at least partially disposed along one side of the interlayer channel320. The isolating glue strip910connects the protecting layer500that protrudes over the side edge310of the display layer300, such as the end edge510of the protecting layer500, with the carrying surface110to isolate the filling glue900within the interlayer channel320from the filling glue900outside the interlayer channel320. The viscosity of the first isolating glue strip910before hardening is greater than the viscosity of the filling glue900before hardening. More particularly, in the manufacturing process, at least one cutting line120will be formed on the carrying surface110before filling the filling glue, which is benefit to separate and de-bond the plurality products (i.e., the display devices) from the carrying substrate200after the process is complete. In other words, no cutting line will be shown on the products. When liquid filling glue900contacts a portion of the interlayer channel320, it flows to other portions of the interlayer channel320due to capillary attraction. Thus, the cutting line120might be covered by the filling glue900and the separating and de-bonding of the plurality products (i.e., the display devices) from the carrying substrate200after the process is complete might be effected. The first isolating glue strip910can prevent the filling glue900from flow to and cover the cutting line120. Further, as the embodiment shown inFIG. 6A, one end of the first isolating glue strip910close to the electronic unit700extends to connect electronic unit700. By extending and connecting to the electronic unit700, the first isolating glue strip910forms a first glue filling area121on the carrying surface110for filling the filling glue900in the manufacturing process. When liquid filling glue900contacts a portion of the interlayer channel320, it flows to other portions of the interlayer320due to capillary attraction. Since the range of the first glue filling area121is fixed, the filling amount of the liquid filling glue can be controlled by directly filling the filling glue900into the first glue filling area121, to prevent the filling glue900from flowing to and covering the cutting line120due to excess filling amount of the filling glue900.

In different embodiments, the shape of the display can differ in accordance with the design requirements. For example, as the embodiment shown inFIG. 7, the display layer300includes two protruding parts311disposed apart and symmetrically, wherein the electronic unit700is disposed between the protruding parts311. In other words, the area of the display layer300is increased by the disposition of the protruding parts311, hence the display area of the display device800can be increased.

As the embodiment shown inFIG. 7, the interlayer channel320and the first isolating glue strip910are disposed along the sides of the protruding parts311that face the electronic unit700. The display device800further includes a second isolating glue strip920surrounding the electronic unit700, wherein the viscosity of the second isolating glue strip920before hardening is greater than the viscosity of the filling glue900before hardening. One end of the first isolating glue strip910closer to the electronic unit700extends to connect with the second isolating glue strip920. By extending and connecting to the second isolating glue strip920, the first isolating glue strip910forms a first glue filling area121on the carrying surface110for filling the filling glue900in the manufacturing process. More particularly, when liquid filling glue900contacts a portion of the interlayer channel320, it flows to other portions of the interlayer320due to capillary attraction. Since the range of the first glue filling area121is fixed, the filling amount and the distribution area of the liquid filling glue can be controlled by directly filling the filling glue900into the first glue filling area121.

As the embodiment shown inFIG. 7, the display device800further includes a third isolating glue strip930disposed in the area enclosed by the cutting lines120on the carrying surface110, wherein the third isolating glue strip930does not overlap the cutting line120. Two opposite ends of the third isolating glue strip930respectively connect to the first isolating glue strips910extending along the side of the two protruding parts311to enclose an area, such as the second glue filling area122shown inFIG. 7. The viscosity of the third isolating glue strip930before hardening is greater than the viscosity of the filling glue900before hardening. Since the range of the second glue filling area122is fixed, the filling amount and the distribution area of the liquid filling glue can be controlled by directly filling the filling glue900into the second glue filling area122.

In different embodiments, the protecting layer500is flush with the display layer300at or close to the intersection of the interlayer channel320and the cutting line120to interrupt the interlayer channel320, preventing the filling glue900from flowing to and covering the cutting line120. As the embodiment shown inFIGS. 8A and 8B, whereinFIG. 8Bis a partial view ofFIG. 8A, a cutting line120is formed on the carrying surface110, and one end of the interlayer channel320extends toward the cutting line120. The display layer300includes two protruding parts311disposed apart and symmetrically, wherein the electronic unit700is disposed between the protruding parts311. The interlayer channel320is disposed along the sides of the protruding parts311facing the electronic unit700and stops at the bottom end of the protruding parts311. More particularly, as shown inFIG. 5, the bottom side511of the protecting layer500that protrudes over the display layer300, the side edge310of the display layer300, and the carrying surface110of the flexible substrate100respectively form three faces of the interlayer channel320. However, as shown inFIGS. 8A and 8B, the end edge510of the protecting layer500is flush with the side edge310of the display layer300at the bottom end of the protruding parts311before the interlayer channel320intersects the cutting line120. That is, the end edge510of the protecting layer500is aligned with the side edge310of the display layer300in this position. As such, one face (the bottom side511of the end edge510of the protecting layer500protruding over the side edge310of the display layer300) of forming the interlayer channel320no longer exists, therefore the interlayer channel320is interrupted at this position. The display device800further includes a third isolating glue strip930disposed on the carrying surface110and extending along the sides of the two protruding parts311, wherein the two opposite ends of the third isolating glue strip930respectively connect to where the interlayer channel320is interrupted to enclose an area, e.g. the third glue filling area123shown inFIG. 8A. The viscosity of the third isolating glue strip930before hardening is greater than the viscosity of the filling glue900before hardening. Since the range of the third glue filling area123is fixed, the filling amount and the distribution area of the liquid filling glue can be controlled by directly filling the filling glue900into the third glue filling area123.

The above approach that the protecting layer500is flush with the display layer300at a place close to the intersection of the interlayer channel320and the cutting line120to interrupt the interlayer channel320can also be applied to the embodiment having no protruding parts shown inFIGS. 8C and 8D, whereinFIG. 8Dis a partial view ofFIG. 8C. In this embodiment, bevel angles are formed at two corners in the bottom of the protecting layer500, wherein the protecting layer500is flush with the display layer300at the beveled corners and close to the intersection of the interlayer channel320and the cutting line120to interrupt the interlayer channel320. Accordingly, this approach not only controls the amount of the filling glue900filled in to the first glue filling area121in the process, but also prevents the filling glue900from flowing to and covering the cutting line120by interrupting the interlayer channel320.

In different embodiments, the protecting layer500forms at least one opening520at or close to the intersection of the interlayer channel320and the cutting line120to interrupt the interlayer channel320for preventing the filling glue900from flowing to and covering the cutting line120. More particularly, as the embodiment shown inFIGS. 9A and 9B, whereinFIG. 9Bis a partial view ofFIG. 9A, a cutting line120is formed on the carrying surface110, wherein one end of the interlayer channel320extends toward the cutting line120, wherein the protecting layer500forms an opening520at or close to the intersection of the interlayer channel320and the cutting line120. As shown inFIG. 5, the bottom side511of the protecting layer500that protrudes over the side edge310of the display layer300, the side edge310of the display layer300, and the carrying surface110respectively form three faces of the interlayer channel320. Forming the opening520will cause that one face (the bottom side511of the protecting layer500protruding over the display layer300) of forming the interlayer channel320no longer exists, the interlayer channel320is interrupted, and therefore the capillary attraction will be interrupted also. The display layer300includes two protruding parts311disposed apart and symmetrically, wherein the electronic unit700is disposed between the protruding parts311. The interlayer channel320is disposed along the sides of the protruding parts311facing the electronic unit700and is interrupted by the opening520at the bottom end of the protruding parts311. The display device800further includes a third isolating glue strip930disposed on the carrying surface110, wherein the two opposite ends of the third isolating glue strip930respectively connect to the openings520at the bottom end of the protruding parts311to enclose an area, e.g. the third glue filling area123shown inFIG. 9A. The viscosity of the third isolating glue strip930before hardening is greater than the viscosity of the filling glue900before hardening. Since the range of the third glue filling area123is fixed, the filling amount and the distribution area of the liquid filling glue can be controlled by directly filling the filling glue900into the third glue filling area123.

In different embodiments, the display device800further includes an isolating glue block940disposed at or close to the intersection of the interlayer channel320and the cutting line120on the carrying surface110to interrupt the interlayer channel320for preventing the filling glue900from flowing to and covering the cutting line120. More particularly, as the embodiment shown inFIGS. 10A and 10B, whereinFIG. 10Bis a partial view ofFIG. 10A, a cutting line120is formed on the carrying surface110, wherein one end of the interlayer channel320extends toward the cutting line120. The isolating glue block940is disposed before the intersection of the interlayer channel320and the cutting line120to interrupt the interlayer channel320. The viscosity of the isolating glue block940before hardening is greater than the viscosity of the filling glue900before hardening.

As a different embodiment shown inFIG. 11A, the protecting layer500of the display device800has an end edge510, wherein the side edge310of the display layer300exceeds the end edge510of the protecting layer500, and the filling glue900covers a portion of the top surface of the display layer300. In other words, the space400is completely exposed. Thus, the filling glue900can be disposed more conveniently. The ratio of the length L2of the portion of the side edge310of the display layer300exceeding the end edge510of the protecting layer500and the thickness T of the display layer300is between 18.63 and 31.05 for enhancing the fixing effect between the filling glue900and the covered portion of the display layer300.

In the preferred embodiment, the filling glue is a glue body capable of absorbing energy to transform from liquid state to solid state. However, as the different embodiment shown inFIG. 11B, the filling glue900can be a film capable of being bent and inserted into to the space400. The film could be implemented as a plurality of films (as shown inFIG. 11B) or a single film. The film preferably forms a concave part in the space400when the film is inserted into the space400, wherein the top face of the concave part is as high as the protecting layer500to facilitate a vacuum sucking action in the manufacturing process.

As the different embodiment shown inFIG. 11C, the filling glue900includes a glue body901and a film902. The glue body901is filled in the space400and connected with the side edge310of the display layer300, the electronic unit700, and the carrying surface110, wherein the glue body901is capable of absorbing energy to transform from liquid state to solid state. The film902covers and adheres to a portion of the top surface of the protecting layer500and the top surface of the glue body901for enhancing the fixing effect between the protecting layer500and the glue body901.

As a preferred embodiment shown inFIG. 12, the display device manufacturing method of the present invention includes the following steps.

Step1010involves forming a cutting line on a carrying surface of a flexible substrate. More particularly, a flexible substrate100disposed on the carrying substrate200as shown inFIG. 2is provided, wherein the cutting lines120on the carrying surface110of the flexible substrate shown inFIG. 6Aare formed by approaches such as laser cutting.

Step1030involves disposing a display layer on the carrying surface, wherein the display layer has a side edge. More particular, the display layer300having a side edge310is disposed on the carrying surface110as shown inFIG. 2by semiconductor processing steps such as deposition, photolithography, etching, thermal processes, etc.

Step1050involves forming a protecting layer on the opposite side of the display layer with respect to the carrying surface, wherein the protecting layer has an end edge. More particular, the protecting layer500having an end edge510is disposed on the opposite side of the display layer300with respect to the carrying surface110as shown inFIG. 2by semiconductor processing steps such as deposition, photolithography, etching, thermal processes, etc.

Step1070involves disposing an electronic unit on the carrying surface to form a space between the electronic unit and the display layer, wherein the electronic unit and the display layer are disposed on the same side of the cutting line. More particular, the electronic unit700is disposed on the carrying surface110as shown inFIG. 2by semiconductor processing steps such as deposition, photolithography, etching, thermal processes, etc. As shown inFIG. 6A, the electronic unit700and the display layer300are on the same side of the cutting line120.

Step1090involves filling a filling glue in the space, wherein the filling glue is connected with the side edge of the display layer, the electronic unit, and the carrying surface. More particularly, the filling glue can be a liquid that can be solidified by approaches such as UV light illuminating or heating. In this step, the filling glue900is filled into the space400by approaches such as injecting, dripping, spraying, and then be solidified.

Step1110involves taking out a portion of the flexible substrate carrying the display layer and the electronic unit according to the cutting line. More particularly, the flexible substrate100as well as the carried display layer300and the electronic unit700in the area enclosed by the cutting line120as shown inFIG. 6Ais taken out.

In the preferred embodiment, step1050includes making the end edge510of the protecting layer500not exceed the side edge310of the display layer300as shown inFIG. 2. Step1090includes making the filling glue900partially overflow the space400and covers a portion of the top surface of the protecting layer500as shown inFIG. 2. Step1090includes making the filling glue900partially overflow the space400and covers a portion of the top surface of the electronic unit700as shown inFIG. 2. Step1090includes making the filling glue900surround the electronic unit700as shown inFIG. 4.

In different embodiments, step1050includes making the end edge510of the protecting layer500extend out of the side edge310of the display layer300, wherein the portion of the end edge510of the protecting layer500that extends out of the side edge310of the display layer300forms an interlayer channel320with the carrying surface110along the extending direction of the of the display layer300310as shown inFIG. 5. Step1090includes making the filling glue900contained in the interlayer channel320as shown inFIG. 5. At this time, as the flow charts of different embodiments shown inFIGS. 13A-13B, the display device manufacturing method further includes step1081of disposing a first isolating glue strip at least partially along one side of the interlayer channel, wherein the isolating glue strip connects the portion of the end edge of the protecting layer extending out of the side edge of the display layer with the carrying surface to isolate the filling glue within the interlayer channel from the filling glue outside the interlayer channel. The viscosity of the first isolating glue strip before hardening is greater than the viscosity of the filling glue before hardening. More particularly, the first isolating glue strip910is preferably sticky semi-solid/semi-liquid material before hardening. The first isolating glue strip910can be disposed at least partially along one side of the interlayer channel320by approaches such as smearing, and connects the portion of the end edge510of the protecting layer500that extends out of the side edge310of the display layer300with the carrying surface110to isolate the filling glue900within the interlayer channel320from the filling glue900outside the interlayer channel320as shown inFIG. 6B. Step1090includes determining the filling amount of the filling glue to control the amount of the filling glue filled into the interlayer channel.

In another embodiment, step1050includes making the end edge510of the protecting layer500retreat from the side edge310of the display layer300as shown inFIGS. 11A-11C. Step1090includes making the filling glue900cover the top surface of the display layer300. Step1090includes filling a glue body which is taken as the filling glue900in the space400and respectively connecting with the side edge310of the display layer300, the electronic unit700, and the carrying surface110as shown inFIG. 11A, wherein the glue body is capable of absorbing energy to transform from liquid state to solid state. Step1090includes taking a film capable of being bent as the filling glue900and inserting the film into to fill the space400as shown inFIG. 11B. On the other hand, step1090can includes: filling a glue body901in the space400and respectively connecting with the side edge310of the display layer300, the electronic unit700, and the carrying surface110as shown inFIG. 11C; applying energy onto the glue body901to transform the glue body901from liquid state to solid state; and covering and adhering a film902to a portion of the protecting layer500and the glue body901as shown inFIG. 11C.

As different embodiments shown inFIGS. 13A-13B, the display device manufacturing method of the present invention further includes step1082of disposing a second isolating glue strip surrounding the electronic unit, wherein one end of the first isolating glue strip closer to the electronic unit extends to connect with the second isolating glue strip, wherein the viscosity of the second isolating glue strip before hardening is greater than the viscosity of the filling glue before hardening. More particularly, the second isolating glue strip920is preferably sticky semi-solid/semi-liquid material before hardening. The second isolating glue strip920can surround the electronic unit700and connect with the extended end of the first isolating glue strip910close to the electronic unit700as shown inFIG. 7.

As the embodiment shown inFIG. 7, the side edge310includes two protruding parts311disposed apart and symmetrically, wherein the electronic unit700is disposed between the protruding parts311, and wherein the interlayer channel320and the first isolating glue strip910are disposed along the sides of the protruding parts311facing the electronic unit700. As the different embodiments shown inFIGS. 13A-13B, the display device manufacturing method of the present invention further includes step1083of disposing a third isolating glue strip on the carrying surface, wherein the two opposite ends of the third isolating glue strip respectively connect to the first isolating glue strip extending from the side of the two protruding parts to enclose an area. The viscosity of the third isolating glue strip before hardening is greater than the viscosity of the filling glue before hardening. More particularly, the third isolating glue strip930is preferably sticky semi-solid/semi-liquid material before hardening. The third isolating glue strip930can surround the electronic unit700by approaches such as smearing, be disposed on the carrying surface110, making the two opposite ends of the third isolating glue strip930respectively connect to the first isolating glue strip910extending from the side of the two protruding parts311to enclose an area.

As the different embodiments shown inFIGS. 13A-13B, step1050includes: making one end of the interlayer channel extend toward the cutting line; and cutting the protecting layer and the display layer so that the protecting layer is flush with the display layer at or close to the intersection of the interlayer channel and the cutting line to interrupt the interlayer channel. More particularly, as the embodiment shown inFIG. 8A, the side edge310of the display layer300includes two protruding parts311disposed apart and symmetrically, wherein the electronic unit700is disposed between the protruding parts311. The interlayer channel320is disposed along the sides of the protruding parts311facing the electronic unit700and is interrupted at the bottom end of the protruding parts311. The method further includes step1083of disposing a third isolating glue strip930on the carrying surface110as shown inFIG. 8A, wherein the two opposite ends of the third isolating glue strip930respectively connect to where the interlayer channel320extending along the sides of the two protruding parts311stops to enclose an area. The viscosity of the third isolating glue strip930before hardening is greater than the viscosity of the filling glue900before hardening.

In different embodiments, step1050includes: making one end of the interlayer channel320extend toward the cutting line120; and forming an opening520on the protecting layer500at or close to the intersection of the interlayer channel320and the cutting line120to interrupt the interlayer channel320.FIG. 9Ais a schematic view of an embodiment of forming an opening520on the protecting layer500close to the intersection of the interlayer channel320and the cutting line120and is above the interlayer channel320.