Patent ID: 12213373

MODE FOR INVENTION

The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which various embodiments are shown. This invention may, however, be embodied in many different forms, and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like reference numerals refer to like elements throughout.

When an element or layer is disposed “on” another element or layer, it may be directly disposed on another element or layer, or another layer or another element may be interposed therebetween.

Although the terms “first”, “second”, and the like are used for describing various components, these components are not confined by these terms. These terms are merely used for distinguishing one component from the other components. Therefore, a first component to be mentioned below may be a second component in a technical concept of the disclosure.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, “a”, “an,” “the,” and “at least one” do not denote a limitation of quantity, and are intended to include both the singular and plural, unless the context clearly indicates otherwise. For example, “an element” has the same meaning as “at least one element,” unless the context clearly indicates otherwise. “At least one” is not to be construed as limiting “a” or “an.” “Or” means “and/or.” As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and/or “comprising,” or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.

Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe one element's relationship to another element as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in one of the figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The term “lower,” can therefore, encompasses both an orientation of “lower” and “upper,” depending on the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The terms “below” or “beneath” can, therefore, encompass both an orientation of above and below.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Embodiments are described herein with reference to cross section illustrations that are schematic illustrations of idealized embodiments. 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, embodiments described herein should not be construed as limited to the particular shapes of regions as illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as flat may, typically, have rough and/or nonlinear features. Moreover, sharp angles that are illustrated may be rounded. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region and are not intended to limit the scope of the present claims.

Hereinafter, embodiments of the disclosure will be described with reference to the accompanying drawings.

FIG.1is an exploded perspective view of a display device according to an embodiment,FIG.2is a top plan view of a display device according to an embodiment,FIG.3is an enlarged view of portion A ofFIG.2,FIG.4is a plan layout view illustrating the correspondence between a flexible substrate and a support member,FIG.5is a cross-sectional view taken along line X1-X1′ ofFIG.3,FIG.6is a cross-sectional view of a display device after secondary bending according to an embodiment,FIG.7is a cross-sectional view of a display device after tertiary bending according to an embodiment, andFIG.8is an enlarged view illustrating portions C and C′ ofFIG.5.FIG.5is a cross-sectional view of a display device after primary bending according to an embodiment.

In embodiments, a first direction DR1and a second direction DR2are different directions intersecting each other. In the plan view ofFIG.2, for convenience of description, the first direction DR1that is a vertical direction and the second direction DR2that is a horizontal direction are defined. Further, a third direction DR3that is a thickness direction is defined. In the following embodiments, one side in the first direction DR1represents an upward direction in a plan view, and the other side in the first direction DR1represents a downward direction in a plan view. One side in the second direction DR2represents a direction toward the right side in a plan view, and the other side in the second direction DR2represents a direction toward the left side in a plan view. One side in the third direction DR3represents a display surface (an upper surface in the case of a top-emission display device) and the other side in the third direction DR3represents a surface opposite to the display surface. It should be understood, however, that a direction mentioned in the embodiment refers to a relative direction and the embodiments are not limited to the direction mentioned.

Referring toFIGS.1to8, an embodiment of a display device1may include a cover window member100and a display panel300disposed on a lower portion of the cover window member100. In such an embodiment, the display device1may further include a data driving integrated circuit400mounted on the display panel300and a printed circuit board500.

The display panel300may include a flexible substrate310and an optical member370disposed on the flexible substrate310.

The display panel300may include a planar portion PS, a first side portion SS1, a second side portion SS2, a third side portion SS3, a fourth side portion SS4, a first edge portion ES1, a second edge portion ES2, a third edge portion ES3, a fourth edge portion ES4, a first corner portion CS1, a second corner portion CS2, a third corner portion CS3, a fourth corner portion CS4, and a multi-bent portion PES extending from the second side portion SS2.

The display panel300may include the flexible substrate310.

The flexible substrate310is a flexible substrate that can be bent, folded, rolled, and the like, and may include or be made of plastic. In an embodiment, for example, the flexible substrate310may include polyethersulphone, polyacrylate (PA), polyarylate (PAR), polyetherimide (PEI), polyethylene naphthalate. (PEN), polyethylene terepthalate (PET), polyphenylene sulfide (PPS), polyacrylate, polyimide (PI), polycarbonate (PC), cellulose triacetate (CAT), cellulose acetate propionate (CAP) or combinations thereof. Alternatively, the flexible substrate310may include a metal material having high ductility.

The planar portion PS or an upper surface portion may be a portion that is formed flat without being bent. The planar portion PS may have a quadrilateral planar shape having a pair of short sides in the second direction DR2and a pair of long sides in the first direction DR1. In the planar portion PS, corners where the short sides and the long sides meet may be curved to have a predetermined curvature. The planar portion PS may include a top surface or a display surface (in the case of a top-emission display device) of the display panel300.

The first edge portion ES1may extend from the other side of the flat part PS in the second direction DR2. The first edge portion ES1may be disposed between the planar portion PS and the first side portion SS1. The first edge portion ES1may be a portion that is curved between a first bending line BL1and a fifth bending line BL5with a predetermined curvature. The first bending line BL1may be the boundary between the planar portion PS and the first edge portion ES1and the fifth bending line BL5may be the boundary between the first side portion SS1and the first edge portion ES1.

The first side portion SS1may extend from the other side of the first edge portion ES1in the second direction DR2. The first side portion SS1may include the left side surface of the display panel300. The first side portion SS1may have a quadrilateral planar shape having a pair of short sides extending in the third direction DR3and a pair of long sides extending in the first direction DR1.

The second edge portion ES2may extend from the other side of the planar portion PS in the first direction DR1. The second edge portion ES2may extend from the lower side of the planar portion PS. The second edge portion ES2may be disposed between the planar portion PS and the second side portion SS2. The second edge portion ES2may be a portion that is curved between a secondary bending line BL2and a sixth bending line BL6with a predetermined curvature. The second bending line BL2may be the boundary between the planar portion PS and the second edge portion ES2, and the sixth bending line BL6may be the boundary between the second side portion SS2and the second edge portion ES2.

The second side portion SS2may extend from the other side of the second edge portion ES2in the first direction DR1. The second side portion SS2may include a lower surface of the display panel300. The second side portion SS2may have a quadrilateral planar shape including a pair of short sides in the third direction DR3and a pair of long sides in the second direction DR2.

The third edge portion ES3may extend form one side of the planar portion PS in the first direction DR1. The third edge portion ES3may extend from the upper side of the planar portion PS. The third edge portion ES3may be disposed between the planar portion PS and the third side portion SS3. The third edge portion ES3may be a portion that is curved between a third bending line BL3and a seventh bending line BL7with a predetermined curvature. The third bending line BL3may be the boundary between the planar portion PS and the third edge portion ES3and the seventh bending line BL7may be the boundary between the third side portion SS3and the third edge portion ES3.

The third side portion SS3may extend from one side of the third edge portion ES3in the first direction DR1. The third side portion SS3may include an upper surface of the display panel300. The third side portion SS3may have a quadrilateral planar shape including a pair of short sides in the third direction DR3and a pair of long sides in the second direction DR2.

The fourth edge portion ES4may extend form one side of the planar portion PS in the second direction DR2. The fourth edge portion ES4may extend from the right side of the planar portion PS. The fourth edge portion ES4may be disposed between the planar portion PS and the fourth side portion SS4. The fourth edge portion ES4may be a portion that is curved between a fourth bending line BL4and an eighth bending line BL8with a predetermined curvature. The fourth bending line BL4may be the boundary between the planar portion PS and the fourth edge portion ES4and the eighth bending line BL8may be the boundary between the fourth side portion SS4and the fourth edge portion ES4.

The fourth side portion SS4may extend from the other side of the fourth edge portion ES4in the second direction DR2. The fourth side portion SS4may include the right side surface of the display panel300. The fourth side portion SS4may have a quadrilateral planar shape having a pair of short sides extending in the third direction DR3and a pair of long sides extending in the first direction DR1.

A first corner portion CS1may be disposed between the first edge portion ES1and the second edge portion ES2. Since the first corner portion CS1is not disposed between the first side portion SS1and the second side portion SS2, an empty space may be provided between the first side portion SS1and the second side portion SS2. The width of the first corner portion CS1may be less than the widths of the first edge portion ES1and the second edge portion ES2. A first dead space may be provided on the outside of the first corner portion CS1. The first dead space may be defined as an empty space in a first corner area between the first edge portion ES1and the second edge portion ES2, where the first corner portion CS1may not be disposed.

The second corner portion CS2may be disposed between the first edge portion ES1and the third edge portion ES3. Since the second corner portion CS2is not disposed between the first side portion SS1and the third side portion SS3, an empty space may be provided between the first side portion SS1and the third side portion SS3. The width of the second corner portion CS2may be less than the widths of the first edge portion ES1and the third edge portion ES3. Thus, when viewed from above the flat portion, a second dead space may be provided on the outside of the second corner portion CS2. The second dead space may be defined as an empty space in a second corner area between the first edge portion ES1and the third edge portion ES3, where the second corner portion CS2may not be disposed.

The third corner portion CS3may be disposed between the second edge portion ES2and the fourth edge portion ES4. Since the third corner portion CS3is not disposed between the second side portion SS2and the fourth side portion SS4, an empty space may be provided between the second side portion SS2and the fourth side portion SS4. The width of the third corner portion CS3may be less than the widths of the second edge portion ES2and the fourth edge portion ES4. Thus, when viewed from above the flat portion, a third dead space may be provided on the outside of the third corner portion CS3. The third dead space may be defined as an empty space in a third corner area between the second edge portion ES2and the fourth edge portion ES4, where the third corner portion CS3may not be disposed.

The fourth corner portion CS4may be disposed between the third edge portion ES3and the fourth edge portion ES4. Since the fourth corner portion CS4is not disposed between the third side portion SS3and the fourth side portion SS4, an empty space may be provided between the third side portion SS3and the fourth side portion SS4. The width of the fourth corner portion CS4may be less than the widths of the third edge portion ES3and the fourth edge portion ES4. Thus, when viewed from above the flat portion, a fourth dead space may be provided on the outside of the fourth corner portion CS4. The fourth dead space may be defined as an empty space in a fourth corner area between the third edge portion ES3and the fourth edge portion ES4, where the fourth corner portion CS4may not be disposed.

As shown inFIG.2, in an embodiment, a first intersection point CP1between the first bending line BL1and the second bending line BL2may overlap the first corner portion CS1. In such an embodiment, a strain may be applied to the first corner portion CS1by the bending force of the first edge portion ES1and the first side portion SS1and the bending force of the second edge portion ES2and the second side portion SS2.

In such an embodiment, the first intersection point CP1between the first bending line BL1and the second bending line BL2may be provided not to overlap the first corner portion CS1to prevent the strain from being applied to the first corner portion CS1. In such an embodiment, the first intersection point CP1between the first bending line BL1and the second bending line BL2may be disposed on the outside of the first corner portion CS1. Features of the first intersection point CP1described above equally applies to second to fourth intersection points CP2, CP3and CP4, and thus any repetitive detailed descriptions of the second to fourth intersection points CP2, CP3and CP4will be omitted.

The multi-bent portion PES may extend from the other side of the second side portion SS2in the first direction DR1. The multi-bent portion PES may extend from the lower side of the second side portion SS2.

The multi-bent portion PES may include a plurality of bent portions BS1and BS2that are bent with respect to a plurality of bending lines BL9to BL12with a predetermined curvature. The multi-bent portion PES may further include first and second flat portions FS1and FS2, as well as the plurality of bent portions BS1and BS2. The data driving integrated circuit400and the printed circuit board500may be disposed on the multi-bent portion PES. Each of the bent portions BS1and BS2of the multi-bent portion PES may be bent in a predetermined direction, and the multi-bent portion PES may be disposed in a way such that an end thereof faces the planar portion PS of the display panel300.

The first bent portion BS1may be connected to the second side portion SS2. The first bent portion BS1may be disposed between the first flat portion FS1and the second side portion SS2. The first bent portion BS1may be a portion that is curved between the ninth bending line BL9and the tenth bending line BL10with a predetermined curvature. The ninth bending line BL9may be the boundary between the second side portion SS2and the first bent portion BS1and the tenth bending line BL10may be the boundary between the first bent portion BS1and the first flat portion FS1. The first bent portion BS1may be a portion that is curved at the time of secondary bending of the display device1as will be described below.

The first flat portion FS1may be connected to the first bent portion BS1. The first flat portion FS1may be disposed between the first bent portion BS1and the second bent portion BS2. The first flat portion FS1may have a quadrilateral planar shape including a pair of short sides in the first direction DR1and a pair of long sides in the second direction DR2.

The second bent portion BS2may be connected to the first flat portion FS1. The second bent portion BS2may be disposed between the first flat portion FS1and the second flat portion FS2. The second bent portion BS2may be a portion that is curved between the eleventh bending line BL11and the twelfth bending line BL12with a predetermined curvature. The eleventh bending line BL11may be the boundary between the first flat portion FS1and the second bent portion BS2and the twelfth bending line BL12may be the boundary between the second bent portion BS2and the second flat portion FS2. The second bent portion BS2may be a portion that is bent at the time of tertiary bending of the display device1as will be described below.

The second flat portion FS2may be connected to the second bent portion BS2. The second flat portion FS2may include an end of the multi-bent portion PES. The second flat portion FS2may have a quadrilateral planar shape including a pair of short sides in the first direction DR1and a pair of long sides in the second direction DR2.

The second flat portion FS2may include a first pad area PA1and a second pad area PA2. The first pad area PA1may be disposed between the second bent portion BS2and the end of the second flat portion FS2, and the second pad area PA2may be disposed between the first pad area PA1and the end of the second flat portion FS2. The first pad area PA1may be provided with a plurality of first pads, and the data driving integrated circuit400may be mounted on the first pad. The data driving integrated circuit400may be disposed on the first pad area PA1in the form of a driving integrated chip (IC).

The second pad area PA2may be provided with a plurality of second pads, and the printed circuit board500may be disposed on the second pads. The printed circuit board500and the data driving integrated circuit400may be electrically connected to each other through the second pads.

The window member100may be disposed on the display panel300and may cover the outer side of the display panel300. The window member100may have substantially the same shape as the display panel300. The window member100may include a planar portion100PS, a first side portion100SS1, a second side portion100SS2, a third side portion100SS3, a fourth side portion100SS4, a first edge portion100ES1, a second edge portion100ES2, a third edge portion100ES3, and a fourth edge portion100ES4.

The window member100may include or be made of a transparent material. The window member100may include or be made of, for example, glass or plastic. In ana embodiment where the window member100includes plastic, the window member100may have flexible properties.

The window member100may include, but is not limited to, at least one selected from: polyimide, polyacrylate, polymethyl methacrylate (PMMA), polycarbonate (PC), polyethylene naphthalate (PEN), polyvinylidene chloride, polyvinylidene difluoride (PVDF), polystyrene, ethylene vinyl alcohol copolymer, polyethersulphone, polyetherimide (PEI), polyphenylene sulfide (PPS), polyacrylate, tri-acetyl cellulose (TAC), and cellulose acetate propionate (CAP). The plastic window member100may include one or more of the plastic materials listed above.

In an embodiment where the window member100includes plastic, the window member100may further include coating layers (not shown) disposed on the upper and lower surfaces of the plastic. In one embodiment, the coating layers may be hard-coating layers including an organic layer including an acrylate compound and/or an organic-inorganic composite layer. The organic layer may include an acrylate compound. The organic-inorganic composite layer may be a layer in which an inorganic material, such as silicon oxide, zirconium oxide, aluminum oxide, tantalum oxide, niobium oxide, glass bead, or the like is dispersed in an organic material, such as an acrylate compound. In an alternative embodiment, the coating layers may include a metal oxide layer. The metal oxide layer may include a metal oxide such as titanium oxide, aluminum oxide, molybdenum oxide, tantalum oxide, copper oxide, indium oxide, tin oxide, and tungsten oxide, but is not limited thereto.

The planar portion100PS of the window member100may correspond to the planar portion PS of the display panel300, the side portions100SS1to100SS4of the window member100may correspond to the side portions SS1to SS4of the display panel300disposed adjacent thereto, and the edge portions100ES1to100ES4of the window member100may correspond to the edge portions ES1to ES4of the display panel300disposed adjacent thereto. The shapes of the respective corresponding portions are substantially to the same as each other, and thus any repetitive detailed descriptions thereof will be omitted.

Referring toFIG.4, an embodiment of the display device1may further include a support member350disposed on the display panel300. An adhesive member may be further disposed between the support member350and the display panel300. The adhesive member may include a conventional adhesive or pressure sensitive adhesive. The support member350may be disposed over the entire surface of the display panel300. That is, the support member350may have substantially the same planar shape and size as the display panel300. The support member350may be divided into a plurality of portions that correspond to the plurality of portions PS, ES2, SS2, and PES of the display panel300.

In an embodiment, for example, the support member350may include: a first portion351that corresponds to the planar portion PS, the second edge portion ES2, and the second side portion SS2; a second portion353that corresponds to the first bent portion BS1; a third portion355that corresponds to the first flat portion FS1; a fourth portion357that corresponds to the second bent portion BS2; and a fifth portion359that corresponds to the second flat portion FS2.

The first portion351may be disposed on second surfaces (also referred to as “the other surfaces”) of a first substrate portion311to a third substrate portion313, the second portion353may be disposed on a second surface of a fourth substrate portion314, the third portion355may be disposed on a second surface of a fifth substrate portion315, the fourth portion357may be disposed on a second surface of a sixth substrate portion316, and the fifth portion359may be disposed on a second surface of a seventh substrate portion317.

Each of the portions351,353,355,357, and359of the support member350may have substantially the same planar shape and size as each of the corresponding portions PS, ES2, SS2, BS1, FS1, BS2, and FS2of the display panel300. The portions351,353,355,357, and359of the support member350may be integrally formed with each other as a single unitary indivisible part. As described above, the display panel300may be bent in each of the bent portions BS1and BS2in a predetermined direction, and stress generated in the bent portions may be greater than stress generated in the flat portion. Since the support member350disposed over the entire surface of the display panel300is bonded to the display panel300and bent together, the stress may vary according to the physical properties, arrangement, and shape of the support member350. Accordingly, in an embodiment, the support member350may be formed in a way such that the thicknesses of the portions353and357respectively bonded to the bent portions BS1and BS2of the display panel300are less than the thicknesses of the other adjacent portions351,355, and359, thereby reducing the stress of the display device1generated in the multi-bent portion PES. The thickness and shape of each of the portions351,353,355,357, and359of the support member350will be described below.

FIG.5illustrates a primary bending state in which the second edge portion ES2of the display panel300is bent and the multi-bent portion PES is unfolded,FIG.6illustrates a secondary bending state in which the second edge portion ES2and the first bent portion BS1of the display panel300are bent and the first flat portion FS1, the second bent portion BS2, and the second flat portion FS2are unfolded, andFIG.7illustrates a tertiary bending state in which the second edge portion ES2, the first bent portion BS1, and the second bent portion BS2of the display panel300are bent.

First, referring toFIG.5, in the primary bending state, the flexible substrate310may be disposed along the planar portion PS, the second edge portion ES2, the second side portion SS2, and the multi-bent portion PES of the display panel300. The flexible substrate310may include the first substrate portion311disposed along the planar portion PS, the second substrate portion312disposed along the second edge portion ES2, the third substrate portion313disposed along the second side portion SS2, the fourth substrate portion314disposed along the first bent portion BS1, the fifth substrate portion315disposed along the first flat portion FS1, the sixth substrate portion316disposed along the second bent portion BS2, and the seventh substrate portion317disposed along the second flat portion FS2.

The second substrate portion312of the flexible substrate310may be bent in a way such that the third substrate portion313is bent from the first substrate portion311, extending in the first direction DR1, toward the other side in the third direction DR3, and the third substrate portion313to the seventh substrate portion317of the flexible substrate310may be extended in the other side in the third direction DR3.

The flexible substrate310may have a first surface (also referred to as “one surface”) facing the window member100and the second surface that is opposite to the first surface.

The support member350described above may be disposed on the second surface of the flexible substrate310. The support member350and the flexible substrate310may be bonded to each other by an adhesive member or the like disposed between the support member350and the second surface of the flexible substrate310.

The first portion351of the support member350may be disposed on the second surfaces of the first substrate portion311, the second substrate portion312, and the third substrate portion313, the second portion353may be disposed on the second surface of the fourth substrate portion314, the third portion355may be disposed on the second surface of the fifth substrate portion315, the fourth portion357may be disposed on the second surface of the sixth substrate portion316, and the fifth portion359may be disposed on the second surface of the seventh substrate portion317.

The thickness of the second portion353of the support member350may be less than the thicknesses of the first portion351and the third portion355. Further, the thickness of the fourth portion357of the support member350may be less than the thicknesses of the third portion355and the fifth portion359adjacent thereto.

In an embodiment, as shown inFIG.8, the first portion351may have a first thickness t1from the second surface of the third substrate portion313of the flexible substrate310. In In such an embodiment, a surface351aof the first portion351may have a surface height corresponding to the first thickness t1from the second surface of the third substrate portion313.

The third portion355may have the first thickness t1from the second surface of the fifth substrate portion315of the flexible substrate310. In such an embodiment, a surface355aof the third portion355may have a surface height corresponding to the first thickness t1from the first surface of the fifth substrate portion315.

The fifth portion359may have the first thickness t1from the second surface of the seventh substrate portion317of the flexible substrate310. In such an embodiment, a surface359aof the fifth portion359may have a surface height corresponding to the first thickness t1from the first surface of the seventh substrate portion317.

The second portion353may have a second thickness t2from the second surface of the fourth substrate portion314. In such an embodiment, a surface of the second portion353may have a surface height corresponding to the second thickness t2from the second surface of the fourth substrate portion314.

The fourth portion357may have a third thickness t3from the second surface of the sixth substrate portion316. In such an embodiment, a surface of the fourth portion357may have a surface height corresponding to the third thickness t3from the first surface of the sixth substrate portion316.

The second thickness t2may be less than the first thickness t1. Further, the third thickness t3may be less than the first thickness t1. such an embodiment, the second portion353and the fourth portion357may be recessed portions which have the surface heights recessed below the surfaces of the adjacent portions351,355, and359.

The recessed portions may be formed by thermal compression using a heat block, which will be described below, in the manufacturing process. When the heat block having a tip with the same shape, width, and compression depth is used, the second portion353and the fourth portion357may be formed to have the same thickness and width as each other. In this case, the second thickness t2and the third thickness t3may be equal to each other, the second portion353may have a first width w1and the fourth portion357may have a second width w2. The first width w1and the second width w2may be equal to each other.

Burrs361or burr shaped portions may be further located on the surface351aof the first portion351, the surface355aof the third portion355, and the surface359aof the fifth portion359. The burrs361may have a shape protruding in the thickness direction from the surface351a,355a, and359a. When the recessed portions353and357are formed through the above-described heat block, a material of the support member350in the corresponding portions may be melted by the heat of the heat block and moved, which may form the burrs361.

The optical member370may be further disposed between the flexible substrate310and the window member100. The optical member370may be disposed on the first substrate portion311to the third substrate portion313, a portion thereof may be disposed on the fourth substrate portion314. The optical member370may not be disposed on the fifth substrate portion315to the seventh substrate portion317.

The optical member370may include a polarizing film.

A bending protective layer380may be further disposed between the optical member370and the data driving integrated circuit400. The bending protective layer380may be in contact with one side surface of the optical member370and may not be in contact with the data driving integrated circuit400.

As shown inFIG.6, an embodiment of the display panel300is subjected to secondary bending after primary bending. During the secondary bending, as the first bent portion BS1is bent at a predetermine curvature from the second side portion SS2extending in the third direction DR3, the fourth substrate portion314may be bent at a first curvature from the third substrate portion313extending in the third direction DR3. Accordingly, the second surfaces of the fifth substrate portion315to the seventh substrate portion317may face the second surface of the first substrate portion311. The first curvature may be less than a second curvature which will be described below. That is, the fourth substrate portion314and the second portion353bonded thereto may be bent at a curvature that is less than the curvature of the sixth substrate portion316and the fourth portion357bonded thereto.

The support member350may have a first surface (also referred to as “one surface”) facing the flexible substrate310and a second surface (also referred to as “the other surface”) that is an opposite surface of the first surface defined.

When the secondary bending is performed, the second surfaces of the third portion355, the fourth portion357, and the fifth portion359may each face the second surface of the first portion351.

As described above, the second portion353of the support member350has a thickness smaller than those of the adjacent first portion351and the third portion357, so that, during the secondary bending, the occurrence of bending stress may be reduced by the second portion353of the support member350.

Then, as shown inFIG.7, the display panel300is subjected to tertiary bending after the secondary bending. During the tertiary bending, as the second bent portion BS2is bent at a predetermine curvature from the first flat portion FS1extending in the third direction DR3, the sixth substrate portion316may be bent at a predetermined curvature from the fifth substrate portion315extending in the third direction DR3. Accordingly, the second surface of the fifth substrate portion315may face the second surface of the third substrate portion313, and the second surface of the seventh substrate portion317may face the second surface of the first substrate portion311.

When the tertiary bending is performed, the second surface of the third portion355may face the second surface of the first portion351. In some embodiments, the second surface of the third portion355may be in contact with the second surface of the first portion351. In addition, although the second surface of the fourth portion357and the second surface of the first portion351may face each other, the second surface of the fourth portion357and the second surface of the first portion351may not be in contact with each other as shown inFIG.8. In addition, the second surface of the fifth portion359may face the second surface of the first portion351. In some embodiments, the second surface of the fifth portion359may be in contact with the second surface of the first portion351.

In some embodiments, the second surface of the fourth portion357and the second surface of the first portion351are not in contact with each other, while the second surface of the adjacent third portion355and the second surface of the first portion351are in contact with each other and the second surface of the fifth portion359and the second surface of the first portion351are in contact with each other. Accordingly, the second surface of the fourth portion, the side surface of the adjacent third portion355, the side surface of the fifth portion359, and the second surface of the first portion351may form an empty space, or a void.

As a result, as shown inFIG.7, the first bent portion BS1is substantially inverted approximately 180 degrees along the first curvature so that the second surface of the portion of the second portion353in contact with the second side portion SS2and the second surface of the portion of the second portion353in contact with the first flat portion FS1may face each other. In addition, the second bent portion BS2may be substantially bent at approximately 90 degrees along the second curvature.

The data driving integrated circuit400and the printed circuit board500may be disposed to overlap the first substrate portion311.

As described above, in embodiments, the fourth portion357of the support member350has a thickness smaller than those of the third portion355and the fifth portion359adjacent thereto, so that, during the tertiary bending, the occurrence of bending stress may be reduced by the fourth portion357of the support member350.

According to embodiments of the display device1, the support member350bonded onto the display panel300is not subjected to processing, such as reducing thickness or the like, except for the second portion353and the fourth portion357that are bent portions, so that the area of an empty space or void formed inside the support member350may be substantially reduced even when the secondary bending and the tertiary bending are performed. If the area of the empty space or void formed inside the support member350is large, foreign substances and/or moisture may enter through the empty space or the void. In such embodiments, the support member350may have the recessed portions selectively formed only in the portions where the secondary bending and the tertiary bending are performed, so that an undesired increase in the formation area of an empty space or a void can be prevented, thereby effectively preventing the introduction of foreign substances and/or moisture permeation.

Hereinafter, a method for manufacturing a display device according to an embodiment will be described in detail. In such an embodiment, the same or like components as those of the above-described embodiment are labeled by the same reference numerals, and any repetitive detailed description thereof will be omitted or simplified for descriptive convenience.

FIG.9is a flowchart illustrating a method for manufacturing a display device according to an embodiment, andFIGS.10to13are sequential cross-sectional views illustrating a method for manufacturing a display device according to an embodiment.

Referring toFIGS.9and10in conjunction withFIGS.5to7, in an embodiment of a method for manufacturing a display device, the flexible substrate310, which has a first surface (also referred to as “one surface”) and a second surface (also referred to as “the other surface”) that is an opposite surface of the first surface, and the support member350adisposed over the entire surface of the second surface of the flexible substrate310are prepared, where the flexible substrate310includes the first substrate portion311extending in the first direction DR1, the second substrate portion312connected to the first substrate portion311, the third substrate portion313connected to the second substrate portion312, the fourth substrate portion314connected to the third substrate portion313, the fifth substrate portion315connected to the fourth substrate portion314, the sixth substrate portion316connected to the fifth substrate portion315, and the seventh substrate portion317connected to the sixth substrate portion316, and the support member350aincludes the first portion351disposed on the second surfaces of the first substrate portion311to the third substrate portion313, the second portion353disposed on the second surface of the fourth substrate portion314, the third portion355disposed on the second surface of the fifth substrate portion315, the fourth portion357disposed on the second surface of the sixth substrate portion316, and the fifth portion359disposed on the second surface of the seventh substrate portion317(S10).

As shown inFIG.10, in the operation S10of preparing the flexible substrate310and the support member350a, the first substrate portion311to the seventh substrate portion317are extended in the first direction DR1without being bent.

In such an embodiment, the first portion351to the fifth portion359are extended in the first direction DR1without being bent during the preparation operation. The support member350amay have a first surface (also referred to as “one surface”) facing the flexible substrate310and a second surface (also referred to as “the other surface”) that is the opposite surface of the first surface, and the second surfaces of the first portion351to the fifth portion359may be flat.

A carrier film SF may be further disposed on the second surface of the support member350a.

Referring toFIGS.9and11in conjunction withFIG.4, the data driving integrated circuit400is disposed on the first surface of the pad area of the flexible substrate310(S20). The portion where the data driving integrated circuit400may be the second flat portion FS2ofFIG.4as described above.

In the operation S20of disposing the data driving integrated circuit400may be performed after a first stage ST1is disposed on the other side of the carrier film SF in the third direction DR3.

According to an embodiment of the method for manufacturing a display device, an operation of forming a recessed portion in the support member350ais performed after the operation of mounting the data driving integrated circuit400, and thus the thickness of the support member350ais uniform on the multi-bent portion PES of the display device1. Accordingly, when the data driving integrated circuit400is mounted, a step difference between the portion corresponding to the bent portion of the support member350aand the adjacent portion may not occur, and thus the data driving integrated circuit400may be more easily mounted.

When the above operation is complete, the first stage ST1is removed and the carrier film SF is peeled off from the support member350a.

Then, referring toFIGS.9and12, the second substrate portion312of the flexible substrate310is subjected to a primary bending (S30).

In one embodiment, the operation of bending the second substrate portion312may include bending the second substrate portion312along the curved surface of a curved window100by disposing the curved window member100on the first surface of the flexible substrate310.

When the second substrate portion312is subjected to the primary bending, the second substrate portion312is bent from the first substrate portion311, extending in the first direction DR1, toward the other side in the third direction DR3, so that the portions spaced apart from the first substrate portion311with the second substrate portion312interposed therebetween may extend in the third direction DR3. The flexible substrate310and the support member350ahave substantially the same shape as each other except that the second portion353and the fourth portion357do not have a recessed portion, and thus any repetitive detailed description thereof will be omitted.

Then, referring toFIGS.9and13, in conjunction withFIG.5, the thicknesses of the second portion353and the fourth portion357are made smaller than those of the portions351,355, and359adjacent thereto (S40).

In an embodiment, the operation S40may include forming a recessed portion in each of the second portion353and the fourth portion357.

The operation S40of making the thicknesses of the second portion353and the fourth portion357smaller than those of the portions351,355, and359adjacent thereto may be performed by using a heat block600. The heat block600may include a first tip portion TP1. The heat block600moves in the first direction DR1and applies heat when the first tip portion TP1comes into contact with the support member350aand applies pressure to the support member350a. The support member350amay have a recessed portion that corresponds to the first tip portion TP1of the heat block600. When the pressure is applied to the support member350athrough the heat block600, the display device including the support member350amay be pushed away in the direction in which the pressure is applied. Accordingly, in an embodiment, a second stage ST2may be disposed on the outer side of the display device (i.e., on the upper surface of the window member100and one the display surface of the display panel300) to prevent the support member350afrom being pushed away in the direction in which the pressure is applied. The second stage ST2partially in contact with the outer profile of the display device may fix the display device to which a pressure is applied by the heat block600to prevent the display device from being pushed away. Since physical damage occurs when the corresponding area where the data driving integrated circuit400and the printed circuit board500are disposed is in direct contact with the second stage ST2, the second stage ST2may further include a groove GR recessed toward another aide in the first direction DR1to avoid interference or direct contact with the data driving integrated circuit400and the printed circuit board500.

The operation of forming the recessed portion in each of the second portion353and the fourth portion357may be performed by forming the recessed portion in the fourth portion357after forming the recessed portion in the second portion353, but the disclosure is not limited to this order.

After the above operations, the display device described inFIG.5is formed. The shape of the support member350ais described above with reference toFIG.5, and hence any repetitive detailed description thereof will be omitted hereinafter.

Then, the display device is subjected to a secondary bending (S50).

The secondary bending S50of the display device is substantially the same as that described above with reference toFIG.6, and hence any repetitive detailed description thereof will be omitted.

Then, the display device is subjected to a tertiary bending (S60).

The tertiary bending S60of the display device is substantially the same as that described above with reference toFIG.7, and hence any repetitive detailed description thereof will be omitted.

In an embodiment, the method for manufacturing a display device may further include disposing a lower cover member, such as a heat dissipation sheet or the like, on the second surface of the first portion of the support member350abetween the operation S30of performing the primary bending of the second substrate portion312of the flexible substrate310, the operation S40of making the thickness of the fourth portion357smaller than the thicknesses of the adjacent portions351,355, and359. In the above operation, the support member350amay not have a recessed portion and have the equal surface height, and thus there is no room for the support member350ato float, so that the lower cover member can be easily attached.

FIG.14is a cross-sectional view illustrating a process of a method for manufacturing a display device according to an alternative embodiment.

The embodiment of the method for manufacturing a display device ofFIG.14is substantially the same as the method for manufacturing a display device according to the embodiment ofFIG.9except that recessed portions are formed simultaneously in a second portion353and a fourth portion357. In such an embodiment, a heat block600_1includes a first tip portion TP1and a second tip portion TP2.

Hereinafter, a method for manufacturing a display device according to an alternative embodiment will be described. In the following embodiment, the same or like components as those of the above-described embodiment are labeled by the same reference numerals, and any repetitive detailed description thereof will be omitted or simplified for descriptive convenience.

FIG.15is a cross-sectional view according to an alternative embodiment based on the embodiment ofFIG.7.

The embodiment of the display device ofFIG.15is substantially the same as the display device ofFIG.8except that a second thickness t2_1of a second portion353_1is smaller than a third thickness t3_1of a fourth portion357_1.

As described with reference toFIGS.7and8, the second portion353_1is bent at a curvature that is less than that of the fourth portion357_1, and thus when the thickness of the second portion353_1is made smaller than the thickness of the fourth portion357_1, the overall bending stress of the display device may be reduced.

FIG.16is a cross-sectional view according to an alternative embodiment based on the embodiment ofFIG.7.

The embodiment of the display device ofFIG.16is substantially the same as the embodiment ofFIG.8except that a first width w1_1of a second portion353_2is greater than a second width w2_1of a fourth portion357_2.

In such an embodiment, other features or components are the same as those described above with reference toFIG.8, and thus any repetitive detailed descriptions thereof will be omitted.

FIG.17is a cross-sectional view according to an alternative embodiment based on the embodiment ofFIG.7.

The embodiment of the display device ofFIG.17is substantially the same as the embodiment ofFIG.8except that a second portion353_3includes a second-first portion353ahaving a second thickness t2, a second-second portion353bpositioned between the second-first portion353aand a first portion351, and a second-third portion353cpositioned between the second-first portion353aand a third portion355and a fourth portion357_3includes a fourth-first portion357ahaving a third thickness t3, a fourth-second portion357bpositioned between the fourth-first portion357aand the third portion355, and a fourth-third portion357cpositioned between the fourth-first portion357aand a fifth portion359.

In such an embodiment, the second-first portion353amay have the second thickness t2, and the second-second portion353band the second-third portion353cmay each have a fourth thickness t4. The fourth thickness t4may have a value between the second thickness t2and the first thickness t1. The fourth thickness t4may gradually increase as the distance from the second-first portion353aincreases.

In such an embodiment, the fourth-first portion357amay have the third thickness t3, and the fourth-second portion357band the fourth-third portion357cmay each have a fifth thickness t5. The fifth thickness t5may have a value between the third thickness t3and the first thickness t1. The fifth thickness t5may gradually increase as the distance from the fourth-first portion357aincreases.

FIG.18is a cross-sectional view according to an alternative embodiment based on the embodiment ofFIG.7.

The embodiment of the display device ofFIG.18is substantially the same as the embodiment ofFIG.8except that a second portion353_4and a fourth portion357_4have curved surfaces.

In such an embodiment, other features or components are the same as those described above with reference toFIG.8, and thus any repetitive detailed descriptions thereof will be omitted.

FIG.19is a cross-sectional view according to an alternative embodiment based on the embodiment ofFIG.7.

The embodiments of the display device ofFIG.19is substantially the same as the embodiment ofFIG.8except that the second portion353and the fourth portion357ofFIG.8are not disposed.

In such an embodiment, a support member may not be disposed on the second surface of the fourth substrate portion314and the second surface of the sixth substrate portion316.

FIG.20is a cross-sectional view according to an alternative embodiment based on the embodiment ofFIG.7.

The embodiment of the display device ofFIG.20is substantially the same as the embodiment ofFIG.8except that the burrs361ofFIG.8are not disposed.

In such an embodiment, recessed portions of the support member may be formed using a cutting device, such as a knife, so that the burrs361are not formed, or the burrs361formed may be removed through a washing liquid, laser, or the like.

FIG.21is a plan layout view of a display device according to an alternative embodiment.FIG.22is a cross-sectional view ofFIG.21.

The embodiment of display device ofFIGS.21and22is substantially the same as the embodiment ofFIG.3except that a data driving integrated circuit400is disposed on a first flat portion FS1.

That is, the data driving integrated circuit400may be disposed on the first flat portion FS1in an overlapping manner.

According to an embodiment, a bending protective layer380may be disposed only on a fourth substrate portion314and a fifth substrate portion315, and may not be disposed on a sixth substrate portion316and a seventh substrate portion317. Accordingly, the cost for materials used to form the bending protective layer380may be reduced. However, the disclosure is not limited thereto, and alternatively, as inFIG.7, the bending protective layer380may also be disposed on the sixth substrate portion316and the seventh substrate portion317. In such an embodiment, the bending protective layer380may cover up to the surface of the data driving integrated circuit400.

FIG.23is a cross-sectional view according to an alternative embodiment based on the embodiment ofFIG.7.

The embodiment of the display device ofFIG.23is substantially the same as the embodiment ofFIG.8except that second surfaces or surfaces of a second portion353_5and a fourth portion357_5include uneven surfaces.

Convex portions of the second portion353_6and the fourth portion357_5may have a first thickness t1, and concave portions thereof may have a thickness that is less than the first thickness t1.

FIG.24is a cross-sectional view according to an alternative embodiment based on the embodiment ofFIG.7.

The embodiment of the display device ofFIG.24is substantially the same as is substantially the same as the embodiment ofFIG.8except that side surfaces of a first portion351, a third portion355, and a fifth portion359adjacent to a second portion353_6and a fourth portion357_6and surfaces or second surfaces of the second portion353_6and the fourth portion357_6include uneven surfaces.

FIG.25is a cross-sectional view of a display device according to an alternative embodiment.

The embodiment of the display device ofFIG.25is substantially the same as the display device ofFIG.7except that a multi-bent portion further includes two more bent portions.

In such an embodiment, a flexible substrate may further include an eighth substrate portion318connected to a seventh substrate portion317, a ninth substrate portion319connected to the eighth substrate portion318, a tenth substrate portion320connected to the ninth substrate portion319, and an eleventh substrate portion321connected to the tenth substrate portion320. In such an embodiment, the support member may further include a sixth portion363connected to a fifth portion359, a seventh portion365connected to the sixth portion363, an eighth portion367connected to the seventh portion365, and a ninth portion369connected to the eighth portion367.

The sixth portion363and the eighth portion367may have thicknesses that are less than those of the adjacent portions.

The sixth substrate portion316may be bent in a vertically inverted form of the fourth substrate portion314, the eighth substrate portion318may be bent in the same way as the fourth substrate portion314, and the tenth substrate portion320may be bent in the same way as the sixth substrate portion316ofFIG.7.

FIG.26is a plan view of a display device according to another embodiment, andFIG.27illustrates cross-sectional views taken along lines X2-X2′ and X3-X3′ ofFIG.26.

The embodiment of the display device1_1shown inFIGS.26and27is substantially the same as the display device1except that the display device1_1is configured as a tiled display device.

In such an embodiment, the display panel300described above with reference toFIG.1is provided in plural and arranged along a matrix direction, and one window member100_1may be disposed on the display panels300.

In such an embodiment, other features or components are substantially the same as those described above, and thus any repetitive detailed descriptions thereof will be omitted.

The invention should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the concept of the invention to those skilled in the art.

While the invention has been particularly shown and described with reference to embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit or scope of the invention as defined by the following claims.