Patent Publication Number: US-2021195765-A1

Title: Display panel, method for manufacturing display panel, and display

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application is a continuation of International Application PCT/CN2019/126538, filed on Dec. 19, 2019, the entire disclosure of which is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     This disclosure relates to the field of display panels, and particularly to a display panel, a method for manufacturing the display panel, and a display. 
     BACKGROUND 
     In recent years, with progress and maturity of flexible technology, a product portfolio of special-shaped screens has been greatly increased. A display panel such as the special-shaped screen generally includes an upper cover, a front plate, and a back plate that are arranged sequentially. The display panel is generally formed as follows: a plate is cut to form a plate body having a specific shape, and then the plate body is bent to obtain the display panel. During bending, folding walls of the display panel need to be bent, whereas a bottom wall of the display panel does not need to be bent. In the related art, a cutting pattern is generally in the shape of a rectangle, and there is a folding dead point between two adjacent folding walls during bending, such that the reliability of the folding walls after being bent is low. 
     Therefore, it is necessary to improve and develop the existing technologies. 
     SUMMARY 
     In view of the above shortcomings in the related art, the disclosure aims to provide a display panel, a method for manufacturing the display panel, and a display, to solve a technical problem that in the related art, there is a folding dead point between two adjacent folding walls during bending, and the reliability of the display panel obtained after the folding walls are bent is low. 
     The technical solution adopted by the disclosure to solve the technical problems is as follows. 
     A display panel is provided. The display panel includes a bottom wall having a display region and folding walls arranged along edges of the bottom wall. A special-shaped graphic region is defined between each two adjacent folding walls to prevent interference during folding of each two adjacent folding walls. Each of the folding walls is bent from the special-shaped graphic region toward a side of the bottom wall away from the display region and fixed to the side of the bottom wall away from the display region. 
     According to the display panel, the special-shaped graphic region includes a first edge, a second edge, a third edge, a fourth edge, and a fifth edge. The first edge and the second edge are respectively located on two adjacent folding walls, the third edge and the fourth edge are located on the bottom wall and respectively connected to the first edge and the second edge, and the fifth edge is connected to the third edge and the fourth edge. 
     According to the display panel, the fifth edge is an arc edge, and a center of a circle where the arc edge is located is at the outside of the special-shaped graphic region. 
     According to the display panel, the special-shaped graphic region satisfies the following relationship: 
     
       
         
           
             
               
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     where N represents the amount of the folding walls, zi1 represents an angle defined between the first edge and an extended line of the third edge, zi2 represents an angle defined between the second edge and an extended line of the fourth edge, and the coefficient m&gt;1. 
     According to the display panel, the coefficient in is selected from a range from 1.1 to 1.5. 
     According to the display panel, the bottom wall includes an upper cover, a front plate, and a back plate that are arranged sequentially. The front plate has a display region for luminous display. 
     According to the display panel, the bottom wall is a flexible plate body. 
     According to the display panel, a light-emitting source in the display region of the front plate is made of inorganic materials. 
     According to the display panel, the bottom wall includes a corner cutting tolerance reserved region arranged around the display region. 
     According to the display panel, the bottom wall further includes a folding tolerance reserved region arranged around the corner cutting tolerance reserved region. 
     According to the display panel, each of the folding walls includes a circuit region arranged around the folding tolerance reserved region and an edge cutting tolerance reserved region arranged around the circuit region. 
     A display is provided. The display includes multiple display panels and a frame, where each of the multiple display panels is the display panel described above. The multiple display panels are sequentially secured to the frame and sequentially electrically coupled with each other. 
     A method for manufacturing the display panel described above is provided. The method includes the following. A plate is provided. A cutting is performed on the plate to obtain a bottom wall and folding walls, where the folding walls are arranged along edges of the bottom wall and fixedly arranged around the bottom wall, and a special-shaped graphic region is defined between each two adjacent folding walls to prevent interference during folding of each two adjacent folding walls. The folding walls are folded to obtain the display panel. 
     According to the method for manufacturing the display panel, the cutting is performed on the plate to obtain the bottom wall and the folding walls as follows. A shape and a size of the special-shaped graphic region are determined. The cutting is performed on the plate according to the shape and the size of the special-shaped graphic region to obtain the bottom wall and the folding walls. 
     According to the method for manufacturing the display panel, the cutting is carried out by laser cutting. 
     The disclosure has the following advantages: since each two adjacent folding walls are cut to form the special-shaped graphic region, no mutual interference occurs during folding of each two adjacent folding walls, and thus no folding dead point is formed, such that the display panel has high reliability. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic structural view of a plate body in the related art. 
         FIG. 2  is a schematic structural view of a display panel in a folding process in the related art. 
         FIG. 3  is a first schematic structural view of a bottom wall and folding walls of the disclosure. 
         FIG. 4  is a schematic structural view of a display panel of the disclosure. 
         FIG. 5  is a second schematic structural view of a bottom wall and folding walls of the disclosure. 
         FIG. 6  is a third schematic structural view of a bottom wall and folding walls of the disclosure. 
         FIG. 7  is an exploded view of a bottom wall of the disclosure. 
         FIG. 8  is a schematic structural view of a bottom wall and folding walls of the disclosure. 
         FIG. 9  is a schematic structural view of a display panel of the disclosure. 
         FIG. 10  is a schematic structural view of a display of the disclosure. 
         FIG. 11  is a schematic flow chart illustrating a method for manufacturing a display panel according to implementations of the disclosure. 
         FIG. 12  is a schematic flow chart illustrating an operation at block  200  illustrated in  FIG. 11  according to implementations. 
     
    
    
     DETAILED DESCRIPTION 
     To describe objectives, technical solutions, and advantages of the disclosure more clearly and completely, the following describes implementations in detail with respect to the accompanying drawings. It should be understood that the implementations described herein are merely intended to explain the disclosure rather than limit the disclosure. 
     As illustrated in  FIG. 3  to  FIG. 10 , implementations of the disclosure provide a display panel. 
     As illustrated in  FIG. 3 ,  FIG. 4 , and  FIG. 7 , a display panel is provided according to the disclosure. The display panel includes a bottom wall  10  having a display region  13  (illustrated in  FIG. 8 ) and folding walls  20  arranged along edges of the bottom wall  10 . The folding walls  20  are fixedly arranged around the bottom wall  10 . A special-shaped graphic region  30  is defined between each two adjacent folding walls  20  to prevent interference during folding of each two adjacent folding walls  20 . The folding wall  20  is bent, from the special-shaped graphic region  30 , toward a side of the bottom wall  10  away from the display region, and fixed to the side of the bottom wall  10  away from the display region. The special-shaped graphic region  30  herein refers to a space region between two adjacent folding walls  20 . Each folding wall  20  can be folded to the back of the bottom wall  10  and is hidden. 
     It can be understood that since each two adjacent folding walls  20  are cut to form the special-shaped graphic region  30 , no mutual interference occurs during folding of each two adjacent folding walls  20 , and thus no folding dead point is formed, and the display panel has high reliability. As illustrated in  FIG. 1  and  FIG. 2 , in the related art, a cutting pattern  3  is generally a rectangle, so that mutual interference may occur during folding of two adjacent folding walls  2 . For example, when one folding wall is over-folded, the other folding wall cannot be folded, or a part of a bottom wall  1  close to the rectangle is warped when folding the other folding wall. For another example, when one folding wall is slightly bent, a size of the bottom wall  1  is increased, and as a result, a width of a frame of a display panel may also be increased. 
     In an implementation of the disclosure, as illustrated in  FIG. 3  and  FIG. 5 , the special-shaped graphic region  30  includes a first edge  31 , a second edge  32 , a third edge  33 , a fourth edge  34 , and a fifth edge  35 . The first edge  31  and the second edge  32  are respectively located on two adjacent folding walls  20 . The third edge  33  and the fourth edge  34  are located on the bottom wall  10  and respectively connected to the first edge  31  and the second edge  32 . The fifth edge  35  is connected to the third edge  33  and the fourth edge  34 . 
     In one example, the first edge  31 , the second edge  32 , the third edge  33 , the fourth edge  34 , and the fifth edge  35  of the special-shaped graphic region  30  coincide with edges of the bottom wall  10  and the folding walls  20 . In addition, the special-shaped graphic region  30  may further include a sixth edge  36  connected to the first edge  31  and the second edge  32 , so that the special-shaped graphic region  30  is a closed graphic region. It can be understood that the sixth edge  36  may be a straight-line edge, an arc edge, or a zigzag edge according to actual needs. Since the sixth edge  36  is cut away, the sixth edge  36  has no impact on the implementation of the disclosure, and thus there is no restriction on the shape of the sixth edge  36 . 
     The first edge  31 , the third edge  33 , the fifth edge  35 , the fourth edge  34 , and the second edge  32  are connected sequentially. The first edge  31  and the second edge  32  may be arranged symmetrically. Similarly, the third edge  33  and the fourth edge  34  may also be arranged symmetrically. Since the third edge  33 , the fourth edge  34 , and the fifth edge  35  are all located on the bottom wall  10 , and the first edge  31  and the second edge  32  are both located on the folding walls  20 , in the plate body, the third edge  33 , the fourth edge  34 , and the fifth edge  35  are coplanar, and the first edge  31  and the second edge  32  are folded and not coplanar with the third edge  33 , the fourth edge  34 , and the fifth edge  35 . Since the third edge  33 , the fourth edge  34 , and the fifth edge  35  are arranged between the first edge  31  and the second edge  32 , that is, a gap is defined between the first edge  31  and the second edge  32 , no mutual interference occurs during folding of the first edge  31  and the second edge  32  and thus no folding dead point is formed. 
     In an implementation of the disclosure, as illustrated in  FIG. 3 , the fifth edge  35  is an arc edge. It is to be understood that the fifth edge  35  may also be a straight-line edge or a zigzag edge. A center of a circle where the arc edge is located is at the outside of the special-shaped graphic region  30 . 
     In one example, the center of the circle where the arc edge is located is on a side of the plate body away from the special-shaped graphic region  30 , that is, on the bottom wall  10 . 
     In an implementation of the disclosure, as illustrated in  FIG. 3 , the special-shaped graphic region  30  satisfies the following relationship: 
     
       
         
           
             
               
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     where N represents the amount of the folding walls  20 , zi1 represents an angle defined between the first edge  31  and an extended line of the third edge  33 , zi2 represents an angle defined between the second edge  32  and an extended line of the fourth edge  34 , and the coefficient m&gt;1. In the special-shaped graphic region  30 , the first edge  31  and the third edge  33  collectively define a concave angle 1, where zi1=concave angle 1-180°, and accordingly, the second edge  32  and the fourth edge  34  collectively define a concave angle 2, where zi2=concave angle 2-180°. 
     In the implementation of the disclosure, the amount N of the folding walls  20  is an integer larger than 2. The larger N is, the closer the shape of the display panel approaches to a circle (as illustrated in  FIG. 6 , “ . . . ” indicates the folding walls  20  and a reserved plate  12  that are not illustrated). Since when triangular display panels (as illustrated in  FIG. 5 ), quadrilateral display panels (as illustrated in  FIG. 7 ), or hexagonal display panels are adopted, the display panels can be connected together to form a complete plane, and no gap is defined among the display panels (as illustrated in  FIG. 10 ), the amount N of the folding walls  20  is preferably set to be 3, 4, or 6. Certainly, display panels (N takes different values) can also be adopted to form a complete plane. 
     In an implementation of the disclosure, the coefficient m is selected from a range from 1.1 to 1.5. 
     In one example, the larger the coefficient m, the larger an angle defined between the first edge  31  and the second edge  32 , and thus interference is not easy to occur during folding. The coefficient m can be set as required. For example, when the coefficient m is set to be 1.2, deployment formulas illustrated in the following table are obtained. 
     
       
         
           
               
               
               
               
             
               
                   
               
               
                   
                 Shape of a display panel 
                 N 
                 Deployment formula 
               
               
                   
               
             
            
               
                   
                 Triangle 
                  3 
                 120° &lt; zi1 + zi2 &lt; 144°  
               
               
                   
                 Quadrilateral 
                  4 
                  90° &lt; zi1 + zi2 &lt; 108°  
               
               
                   
                 . . . 
                 . . . 
                 . . . 
               
               
                   
                 Circle (approaching to 
                 15 
                  24° &lt; zi1 + zi2 &lt; 28.8° 
               
               
                   
                 pentadecagon) 
               
               
                   
               
            
           
         
       
     
     As illustrated in  FIG. 5 , when the display panel is in the shape of a triangle, an angle defined between two adjacent folding walls  20  is an acute angle, the special-shaped graphic region  30  is not in the shape of a triangle, and thus the two adjacent folding walls  20  do not interfere with each other when the two adjacent folding walls  20  are folded to the back of the bottom wall  10 . After the two adjacent folding walls  20  are folded and attached to the back of the bottom wall  10 , the two adjacent folding walls  20  do not overlap with each other, i.e., a thickness of the display panel does not increase. A sum of the angle zi1 and the angle zi2 ranges from 120° to 144° (120°˜144°), that is, the sum of the angle zi1 and the angle zi2 is relatively large. In other words, the first edge  31  and the second edge  32  each may have a relatively large variable range. 
     As illustrated in  FIG. 3 , when the display panel is in the shape of a quadrilateral, an angle defined between two adjacent folding walls  20  is a right angle, the special-shaped graphic region  30  is not in the shape of a quadrilateral, and thus the two adjacent folding walls  20  do not interfere with each other when the two adjacent folding walls  20  are folded to the back of the bottom wall  10 . After the folding walls  20  are folded and attached to the back of the bottom wall  10 , the two adjacent folding walls  20  do not overlap with each other, i.e., the thickness of the display panel does not increase. The sum of the angle zi1 and the angle zi2 ranges from 90° to 108° (90°˜108°). 
     As illustrated in  FIG. 6 , when the display panel is in the shape of a pentadecagon (i.e., the shape of the display panel approaches to a circle), an angle defined between two adjacent folding walls  20  is an obtuse angle, and thus the two adjacent folding walls  20  do not interfere with each other when the two adjacent folding walls  20  are folded to the back of the bottom wall  10 . After the folding walls  20  are folded and attached to the back of the bottom wall  10 , the two adjacent folding walls  20  do not overlap with each other, i.e., the thickness of the display panel does not increase. The sum of the angle zi1 and the angle zi2 ranges from 24° to 28.8° (24°˜28.8°), that is, the sum of the angle zi1 and the angle zi2 is relatively small. In other words, the first edge  31  and the second edge  32  each may have a relatively small variable range. 
     In an implementation of the disclosure, as illustrated in  FIG. 7 , the bottom wall  10  includes an upper cover  10   a , a front plate  10   b , and a back plate  10   c  that are arranged sequentially. The front plate  10   b  has a display region for luminous display. 
     The plate body adopts a three-layer structure. The upper cover  10   a , the front plate  10   b , and the back plate  10   c  are sequentially connected. The upper cover  10   a  and the back plate  10   c  are used for fixing the front plate  10   b . The three layers (i.e., the upper cover  10   a , the front plate  10   b , and the back plate  10   c ) have a substantially same size. During folding, corresponding parts (i.e., folding walls  20 ) of the upper cover  10   a , the front panel  10   b , and the back panel  10   c  are all folded to the back of the bottom wall  10 . 
     In an implementation of the disclosure, in order to facilitate the folding of the plate body, the bottom wall  10  adopts a flexible plate body, so that a size of a frame can be reduced as much as possible to form an unframed display panel. 
     In an implementation of the disclosure, a light-emitting source of the front plate  10   b  is made of inorganic materials. Since when the light-emitting source is made of organic materials, the light-emitting source needs to be packaged with relatively high requirements to avoid water and oxygen, and the folding cannot be performed on a packaging region (once the packaging region is folded, cracks may be formed, and thus water and oxygen may enter the light-emitting source via the cracks). In this case, the packaging region can merely be reserved on the bottom wall, which increases the size of the frame. In the implementation of the disclosure, the light-emitting source of the front plate  10   b  is made of the inorganic materials, and thus the requirement for packaging the light-emitting source is relatively low, and the packaging region can be folded to form the unframed display panel. 
     In an implementation of the disclosure, as illustrated in  FIG. 8 , the bottom wall  10  includes the display region  13  and a corner cutting tolerance reserved region  11  arranged around the display region  13 . The display region  13  is a display region for the front plate  10   b , which can be configured to allow lights emitted by the front plate  10   b  to pass through to display information such as image and text. With the corner cutting tolerance reserved region  11 , the display region  13  is prevented from being cut during cutting, and thus an area or a shape of the display region  13  is not affected. The corner cutting tolerance reserved region  11  has an equidistant frame structure, that is, the width of the frame structure is uniform. 
     In an implementation of the disclosure, as illustrated in  FIG. 8 , the bottom wall  10  further includes a folding tolerance reserved region  12  arranged around the corner cutting tolerance reserved region  11 . The folding tolerance reserved region  12  is configured to provide a reserved position for folding processing. That is, during folding, the first edge  31  and the second edge  32  may be allowed to be partially folded or fully folded. When the first edge  31  and the second edge  32  are fully folded, an ideal state occurs, and in this case, the bottom wall  10  merely has the corner cutting tolerance reserved region  11 , such that the frame has the minimize size. When the first edge  31  and the second edge  32  are partially folded, the worst state occurs, and in this case, the width of the frame is a sum of a width of the corner cutting tolerance reserved region  11  and a width of the remaining folding tolerance reserved region  12 . As can be seen, the width of the frame depends on the width of the folding tolerance reserved region  12 . That is, with setting the width of the folding tolerance reserved region  12 , the width of the frame can be adjusted. As a result, a display panel having a frame of a relatively small size or an unframed display panel can be formed. 
     In addition, during folding, the fifth edge  35  (i.e., corner cutting tolerance reserved region  11 ) is not easily deformed, such that the corner cutting tolerance reserved region  11  can be maintained in a flat state. Since the folding walls  20  do not interfere with each other, no folding dead point may be formed. In addition, with the folding tolerance reserved region  12 , a certain error is allowed during the folding of the folding walls  20 . That is, even if the certain error occurs during the folding of the folding walls  20 , the corner cutting tolerance reserved region  11  may not be affected. In other words, the corner cutting tolerance reserved region  11  is still in the flat state. In this case, an edge distance (i.e., the width of the frame structure) of the corner cutting tolerance reserved region  11  can be reduced as much as possible to obtain the unframed display panel (as illustrated in  FIG. 9 ). Both the third edge  33  and the fourth edge  34  may be arranged to be perpendicular to the corner cutting tolerance reserved region  11  (that is, perpendicular to edges of the corner cutting tolerance reserved region  11 ). 
     In an implementation of the disclosure, as illustrated in  FIG. 8 , each folding wall  20  include a circuit region  21  arranged around the folding tolerance reserved region  12  and an edge cutting tolerance reserved region  22  arranged around the circuit region  21 . Circuits can be arranged in the circuit region  21  to provide electric energy for the light-emitting source. The edge cutting tolerance reserved region  22  can be configured to provide reserved positions for cutting of each edge of the display panel, so as to prevent the circuit region  21  from being cut and avoid damage to the circuits. 
     Implementations of the disclosure further provide a display according to the above implementations for illustrating the display panel. 
     As illustrated in  FIG. 10 , (“ . . . ” in  FIG. 10  represents display panels not illustrated), the display in the implementation of the disclosure includes a frame and at least one display panel provided in the implementation of the disclosure. According to a size of a display actually required, multiple display panels can be selected and fixed to the frame, and the multiple display panels are electrically coupled with each other, to realize an unframed large-screen display. 
     As illustrated in  FIG. 11 , implementations of the disclosure further provide a method for manufacturing a display panel. 
     The method for manufacturing a display panel provided in the implementations of the disclosure begins at block  100 . 
     At block  100 , a plate is provided. 
     In one example, the plate is made from metal or plastic. Generally, a metal plate is used to prepare a back plate. A shape of the plate may be set according to actual needs. For example, when a display panel having a triangular shape needs to be prepared, a triangular plate may be provided. For another example, when a display panel having a hexagonal shape needs to be prepared, a hexagonal plate may be provided. For yet another example, when a display panel having a circular shape needs to be prepared, a circular plate may be provided. 
     At block  200 , a cutting is performed on the plate to obtain a bottom wall and folding walls, where the folding walls are arranged along edges of the bottom wall and fixedly arranged around the bottom wall, and a special-shaped graphic region is defined between each two adjacent folding walls to prevent interference during folding of each two adjacent folding walls. 
     In at least one implementation, as illustrated in  FIG. 12 , the operation at block  200  includes operations at blocks  210 - 220 . 
     At block  210 , a shape and a size of the special-shaped graphic region is determined. 
     In one example, the shape of the special-shaped graphic region needs to be determined according to a shape of the finally formed display panel. For example, when the display panel having the triangle shape needs to be prepared, the shape and the size of the special-shaped graphic region are determined according to the following relationships: 
     
       
         
           
             
               
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     where N represents the amount of the folding walls, zi1 represents an angle defined between a first edge and an extended line of a third edge of the special-shaped graphic region, zi2 represents an angle defined between a second edge and an extended line of a fourth edge of the special-shaped graphic region, and the coefficient m&gt;1. 
     In particular, during preparing the display panel having the circular shape, the amount N of the folding walls needs to be determined according to the size of the finally formed display panel. It can be understood that the larger N is, the closer the shape of the display panel approaches to a circle. That is, the display panel having the circular shape is achieved via a regular N-polygon display panel. 
     At block  220 , the cutting is performed on the plate according to the shape and the size of the special-shaped graphic region to obtain the bottom wall and the folding walls. 
     In at least one implementation, the cutting is carried out by laser cutting. That is, a cutting portion corresponding to the special-shaped graphic region in the plate is cut away to obtain the bottom wall and the folding walls. 
     At block  300 , the folding walls are folded to obtain the display panel. 
     In one example, folding is performed on each folding wall. Each folding wall is bent from the special-shaped graphic region toward a side of the bottom wall away from a display region of the bottom wall, and is fixed to the side of the bottom wall away from the display region. That is, the display region is located on the front of the bottom wall, and the folding walls are folded to the back of the bottom wall. During folding, due to the folding tolerance reserved region, an error is allowed to occur during folding. 
     It is to be noted that the display panel manufactured by the above method is the display panel illustrated in  FIG. 3  to  FIG. 10 . 
     As can be seen, according to the display panel, the method for manufacturing the display panel, and the display that are provided herein, the display panel includes the bottom wall having the display region and the folding walls arranged along the edges of the bottom wall. The folding walls are fixedly arranged around the bottom wall. The special-shaped graphic region is defined between each two adjacent folding walls to prevent interference during folding of each two adjacent folding walls. Each folding wall is bent from the special-shaped graphic region toward the side of the bottom wall away from the display region, and fixed to the side of the bottom wall away from the display region. Since each two adjacent folding walls are cut to form the special-shaped graphic region, no mutual interference occurs during folding of each two adjacent folding walls, and thus no folding dead point is formed, such that the display panel has high reliability. 
     It should be understood that the disclosure is not limited to the above examples. For those of ordinary skill in the art, improvements or changes can be made based on the above description, and all these improvements and changes should fall within the protection scope of the appended claims of the disclosure.