Display device and method of manufacturing the same

This U.S. non-provisional patent application claims priority to, and the benefit of, Korean Patent Application No. 10-2015-0132499, filed on Sep. 18, 2015, the content of which is hereby incorporated by reference in its entirety.

1. Field

The present disclosure relates to a display device and a method of manufacturing the same.

2. Description of the Related Art

A display device displays a variety of images on its display screen to provide a user with information. In recent years, a bendable display device has been developed. The bendable display device is generally either flexible or rigid. When the bendable display device is flexible, a portion of the display device is bent, folded, rolled, or curved like a paper. In addition, when the bendable display device is rigid, the display device may be maintained in a bent state. Different from a flat panel display device, because the bendable display device is deformable into various shapes, the bendable display device is easy to carry, and improves user's convenience.

Aspects of embodiments of the present disclosure are directed to a display device having improved (e.g., increased) durability, and a method of manufacturing the display device.

According to some embodiments of the present inventive concept, there is provided a display device including: a first member; a window on the first member; a first adhesive layer between the first member and the window; and a light blocking layer between the window and the first adhesive layer, the window including: a first window portion contacting the first adhesive layer and including a bending portion and a non-bending portion; and a second window portion connected to the bending portion, the second window portion being spaced from the non-bending portion and contacting the light blocking layer, wherein the first adhesive layer includes: a first adhesive portion including a first sub-adhesive portion contacting the bending portion, and a second sub-adhesive portion contacting the non-bending portion; and a second adhesive portion contacting the light blocking layer, and wherein the first sub-adhesive portion has a modulus that is less than a modulus of each of the second sub-adhesive portion and the second adhesive portion.

In an embodiment, the first sub-adhesive portion has a hardness that is less than a hardness of each of the second sub-adhesive portion and the second adhesive portion.

In an embodiment, the first sub-adhesive portion contacts one side surface of the light blocking layer, and contacts the bending portion.

In an embodiment, the modulus of the second sub-adhesive portion is equal to or less than the modulus of the second adhesive portion.

In an embodiment, the bending portion includes: a first bending portion connected to the non-bending portion; and a second bending portion connected to the non-bending portion and spaced from the first bending portion, and wherein the first sub-adhesive portion includes: a first bending adhesive portion contacting the first bending portion; and a second bending adhesive portion contacting the second bending portion.

In an embodiment, the light blocking layer includes: a first light blocking layer; and a second light blocking layer spaced from the first light blocking layer, wherein the second window portion includes: a first sub-window portion connected to the first window portion and the first light blocking layer; and a second sub-window portion connected to the first window portion and the second light blocking layer, the second sub-window portion being spaced from the first sub-window portion, wherein the second adhesive portion includes: a third sub-adhesive portion contacting the first light blocking layer; and a fourth sub-adhesive portion contacting the second light blocking layer, and wherein a modulus of the first bending adhesive portion and a modulus of the second bending adhesive portion are each less than each of a modulus of the third sub-adhesive portion and a modulus of the fourth sub-adhesive portion.

In an embodiment, the first member includes at least one of a polarizing plate, a display panel, and a touch screen panel.

In an embodiment, the first adhesive layer includes a UV curing agent.

In an embodiment, the first adhesive layer includes at least one of an acrylic-based compound or an acrylic-based copolymer.

In an embodiment, the display device further includes: a second member under the first member; and a second adhesive layer between the first member and the second member.

In an embodiment, the first member includes: a first member portion contacting the first adhesive portion; and a second member portion contacting the second adhesive portion, wherein the second adhesive layer includes: a third adhesive portion contacting the first member portion; and a fourth adhesive portion contacting the second member portion, wherein the first member portion includes: a first bending member portion contacting the first sub-adhesive portion; and a first non-bending member portion contacting the second sub-adhesive portion, wherein the third adhesive portion includes: a fifth sub-adhesive portion contacting the first bending member portion; and a sixth sub-adhesive portion contacting the first non-bending member portion, and wherein the fifth sub-adhesive portion has a modulus that is less than each of a modulus of the sixth sub-adhesive portion and a modulus of the fourth adhesive portion.

In an embodiment, the modulus of the sixth sub-adhesive portion is equal to the modulus of the fourth adhesive portion.

In an embodiment, the modulus of the sixth sub-adhesive portion is less than the modulus of the fourth adhesive portion.

In an embodiment, the second member is different from the first member, and each of the first and second members includes at least one of a polarizing plate, a display panel, and a touch screen panel.

According to some embodiments of the present inventive concept, there is provided a method of manufacturing a display device, the method including: preparing a first adhesive layer including a first adhesive portion and a second adhesive portion, the first adhesive portion including a first sub-adhesive portion and a second sub-adhesive portion; curing the first adhesive layer such that a hardness of the first sub-adhesive portion is less than each of a hardness of the second sub-adhesive portion and a hardness of the second adhesive portion; attaching the first adhesive layer to a light blocking layer and to a window; and attaching the first adhesive layer to a first member, wherein the window includes: a first window portion including a bending portion and a non-bending portion; and a second window portion connected to the bending portion, spaced from the non-bending portion, and contacting the light blocking layer, and wherein the attaching of the window include attaching the first sub-adhesive portion to the bending portion, attaching the second sub-adhesive portion to the non-bending portion, and attaching the second adhesive portion to the second window portion.

In an embodiment, the curing of the first adhesive layer includes: providing a mask above the first adhesive layer; and applying a UV light to the first adhesive layer using the mask.

In an embodiment, the curing of the first adhesive layer is performed before or after the attaching of the first adhesive layer to the light blocking layer and the window.

In an embodiment, the curing of the first adhesive layer is performed such that a modulus of the first sub-adhesive portion is less than each of a modulus of the second sub-adhesive portion and a modulus of the second adhesive portion.

According to the above, the display device may be manufactured to have improved (e.g., increased) durability.

The above and other aspects of the present disclosure will become readily apparent by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

FIG. 1A is a perspective view showing a display device according to an exemplary embodiment of the present disclosure;

FIG. 1B is a cross-sectional view showing the display device shown in FIG. 1A ;

FIG. 2A is a perspective view showing a display device according to an exemplary embodiment of the present disclosure;

FIG. 2B is a cross-sectional view showing the display device shown in FIG. 2A ;

FIG. 3A is a perspective view showing a display device according to an exemplary embodiment of the present disclosure;

FIG. 3B is a cross-sectional view showing the display device shown in FIG. 3A ;

FIG. 4 is a flow diagram showing a method of manufacturing a display device according to an exemplary embodiment of the present disclosure; and

FIGS. 5A-5E are cross-sectional views showing processes of the manufacturing method of the display device according to an exemplary embodiment of the present disclosure.

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 invention 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 will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Hereinafter, the present invention will be explained in detail with reference to the accompanying drawings.

FIG. 1A is a perspective view showing a display device 10 according to an exemplary embodiment of the present disclosure, and FIG. 1B is a cross-sectional view showing the display device 10 shown in FIG. 1A .

Referring to FIGS. 1A and 1B , the display device 10 includes a first member MM 1 , a window WD, a light blocking layer SP, and a first adhesive layer AL 1 . The first member MM 1 may include at least one of a polarizing plate, a display panel, and a touch screen panel. For instance, the first member MM 1 may be the polarizing plate, the display panel, or the touch screen panel. The first member MM 1 may include the display panel, the polarizing plate, and the touch screen panel, which are sequentially stacked along a third direction DR 3 , or may include the display panel and the touch screen panel (while omitting the polarizing plate), which are sequentially stacked along the third direction DR 3 . However, the first member MM 1 should not be limited thereto or thereby. That is, the first member MM 1 may have various suitable stack structures as long as the first member MM 1 includes at least one of the polarizing plate, the display panel, and the touch screen panel.

The display panel may be, but is not limited to, an organic light emitting display panel, a liquid crystal display panel, a plasma display panel, an electrophoretic display panel, a microelectromechanical system (MEMS) display panel, or an electrowetting display panel.

The first member MM 1 may be flexible or rigid. The term “flexible” used herein means that the first member MM 1 may be curved, e.g., the first member MM 1 is fully folded or slightly curved.

The first member MM 1 includes a first member portion MMP 1 and a second member portion MMP 2 . The first member portion MMP 1 and the second member portion MMP 2 are connected to each other, and extend along a second direction DR 2 (which is substantially orthogonal to the third direction DR 3 ). The first member portion MMP 1 makes contact with (e.g., is adhered to) a first adhesive portion ALP 1 . The second member portion MMP 2 is connected to the first member portion MMP 1 . The second member portion MMP 2 makes contact with (e.g., is adhered to) a second adhesive portion ALP 2 . The first member portion MMP 1 includes a first bending member portion BMMP 1 and a first non-bending member portion NMMP 1 . The first bending member portion BMMP 1 is bent with respect to (e.g., about) a bending axis BX extending in a first direction DR 1 (which is orthogonal to the second and third directions DR 2 and DR 3 ). The term “bending” used herein means that the first bending member portion BMMP 1 may be curved by an external force.

The first bending member portion BMMP 1 makes contact with (e.g., is adhered to) a first sub-adhesive portion SALP 1 . The first non-bending member portion NMMP 1 is connected to the first bending member portion BMMP 1 . The first non-bending member portion NMMP 1 may be flat, or unbent. The first non-bending member portion NMMP 1 makes contact with (e.g., is adhered to) a second sub-adhesive portion SALP 2 .

The window WD is disposed on the first member MM 1 . The window WD may be flexible or rigid. The window WD may be, but is not limited to, a cover glass. The window WD may include glass or organic polymer.

The window WD includes a first window portion WDP 1 and a second window portion WDP 2 . The first and second window portions WDP 1 and WDP 2 are connected to each other and generally extend along the second direction DR 2 . The first window portion WDP 1 makes contact with (e.g., is adhered to) the first adhesive layer AL 1 and does not make contact with the light blocking layer SP. The first window portion WDP 1 includes a bending portion BP and a non-bending portion NBP. The bending portion BP is bent with respect to (e.g., about) the bending axis BX extending in the first direction DR 1 . The non-bending portion NBP is connected to the bending portion BP. The non-bending portion NBP may be flat, or unbent.

The second window portion WDP 2 makes contact with the light blocking layer SP and does not make contact with the first adhesive layer AL 1 . The second window portion WDP 2 is connected to the first window portion WDP 1 . The second window portion WDP 2 is spaced from the non-bending portion NBP and is connected to the bending portion BP. The second window portion WDP 2 may be bent with respect to (e.g., about) the bending axis BX, or may be flat without being bent.

The light blocking layer SP is between the window WD and the first adhesive layer AL 1 . The light blocking layer SP may be, but is not limited to, a black matrix. The light blocking layer SP makes contact with the second window portion WDP 2 , and does not make contact with the first window portion WDP 1 .

The first adhesive layer AL 1 is between the first member MM 1 and the window WD. The first adhesive layer AL 1 attaches the first member MM 1 to the window WD. The first adhesive layer AL 1 may include at least one of an acrylic-base compound and/or an acrylic-based copolymer, although the first adhesive layer AL 1 should not be limited thereto or thereby. For example, the first adhesive layer AL 1 may include a UV curing agent.

The first adhesive layer AL 1 includes the first adhesive portion ALP 1 and the second adhesive portion ALP 2 . The first and second adhesive portions ALP 1 and ALP 2 are connected to each other and extend along the second direction DR 2 . The first adhesive portion ALP 1 makes contact with (e.g., is adhered to) the first window portion WDP 1 and the first member portion MMP 1 . The first adhesive portion ALP 1 is attached to (e.g., is adhered to) each of the first window portion WDP 1 and the first member portion MMP 1 to fix (e.g., to attach or to adhere) the first window portion WDP 1 and the first member portion MMP 1 to each other. The second adhesive portion ALP 2 is connected to the first adhesive portion ALP 1 . The second adhesive portion ALP 2 makes contact with (e.g., is adhered to) the light blocking layer SP and the second member portion MMP 2 . The second adhesive portion ALP 2 is attached to (e.g., is adhered to) each of the light blocking layer SP and the second member portion MMP 2 to fix the light blocking layer SP and the second member portion MMP 2 to each other.

The first adhesive portion ALP 1 includes the first sub-adhesive portion SALP 1 and the second sub-adhesive portion SALP 2 . The first and second sub-adhesive portions SALP 1 and SALP 2 are connected to each other and generally extend along the second direction DR 2 . The first sub-adhesive portion SALP 1 makes contact with (e.g., is adhered to) the bending portion BP and the first bending member portion BMMP 1 . The first sub-adhesive portion SALP 1 is attached to the bending portion BP and the first bending member portion BMMP 1 to fix the bending portion BP and the first bending member portion BMMP 1 to each other. The second sub-adhesive portion SALP 2 makes contact with (e.g., is adhered to) the non-bending portion NBP and the first non-bending member portion NMMP 1 . The second sub-adhesive portion SALP 2 is attached to each of the non-bending portion NBP and the first non-bending member portion NMMP 1 to fix the non-bending portion NBP and the first non-bending member portion NMMP 1 to each other.

The first sub-adhesive portion SALP 1 has a modulus (e.g., a modulus of elasticity) that is less than a modulus of each of the second sub-adhesive portion SALP 2 and the second adhesive portion ALP 2 . The first sub-adhesive portion SALP 1 has a hardness that is less than a hardness of each of the second sub-adhesive portion SALP 2 and the second adhesive portion ALP 2 .

The second sub-adhesive portion SALP 2 has substantially the same modulus as that of the second adhesive portion ALP 2 . The second sub-adhesive portion SALP 2 has substantially the same hardness as that of the second adhesive portion ALP 2 . However, according to some embodiments, the modulus of the second sub-adhesive portion SALP 2 may be less than that of the second adhesive portion ALP 2 , and the hardness of the second sub-adhesive portion SALP 2 may be less than that of the second adhesive portion ALP 2 .

The display device 10 according to the present exemplary embodiment may be operated in a first mode and in a second mode. In the first mode, at least a portion of the window WD and the first member MM 1 is bent (e.g., may be bent with respect to, or about, the bending axis BX). The bending of the window WD and the first member MM 1 is stretched out (e.g., flat) in the second mode.

FIG. 2A is a perspective view showing a display device 10 according to an exemplary embodiment of the present disclosure, and FIG. 2B is a cross-sectional view showing the display device 10 shown in FIG. 2A .

Hereinafter, the display device 10 according to the present exemplary embodiment will be described in detail with reference to FIGS. 2A and 2B . In FIGS. 2A and 2B , features of the display device that are different from those of the display device shown in FIGS. 1A and 1B are primarily described.

Referring to FIGS. 2A and 2B , the display device 10 includes a first member MM 1 , a window WD, light blocking layers SP 1 and SP 2 , and a first adhesive layer AL 1 . The first member MM 1 includes at least one of the polarizing plate, the display panel, and the touch screen panel. The first member MM 1 may be flexible or rigid.

The first member MM 1 includes a first member portion MMP 1 and a second member portion MMP 2 . The first member portion MMP 1 and the second member portion MMP 2 are connected to each other, and extend along the second direction DR 2 . The first member portion MMP 1 makes contact with a first adhesive portion ALP 1 . The first member portion MM 1 includes first bending member portions SBMMP 1 and SBMMP 2 and a first non-bending member portion NMMP 1 . The first bending member portions SBMMP 1 and SBMMP 2 respectively make contact with first sub-adhesive portions SSALP 1 and SSALP 2 . The first non-bending member portion NMMP 1 is connected to the first bending member portions SBMMP 1 and SBMMP 2 . The first non-bending member portion NMMP 1 may be flat without being bent. The first non-bending member portion NMMP 1 makes contact with the second sub-adhesive portion SALP 2 .

The first bending member portions SBMMP 1 and SBMMP 2 include a first sub-bending member portion SBMMP 1 and a second sub-bending portion SBMMP 2 . The first sub-bending member portion SBMMP 1 is connected to the first non-bending member portion NMMP 1 . The first sub-bending member portion SBMMP 1 is bent with respect to (e.g., about) a first bending axis BX 1 extending in a first direction DR 1 . The first sub-bending member portion SBMMP 1 makes contact with the first bending adhesive portion SSALP 1 . The second sub-bending member portion SBMMP 2 is connected to the first non-bending member portion NMMP 1 , and is spaced from the first sub-bending member portion SBMMP 1 . The second sub-bending member portion SBMMP 2 is bent with respect to (e.g., about) a second bending axis BX 2 extending in the first direction DR 1 . The second sub-bending member portion SBMMP 2 makes contact with the second bending adhesive portion SSALP 2 .

The second member portion MMP 2 is connected to the first member portion MMP 1 . The second member portion MMP 2 makes contact with a second adhesive portion ALP 2 . The second member portion MMP 2 includes a first sub-member portion SMMP 1 and a second sub-member portion SMMP 2 . The first sub-member portion SMMP 1 is connected to the first member portion MMP 1 . The first sub-member portion SMMP 1 makes contact with a third sub-adhesive portion SALP 3 . The second sub-member portion SMMP 2 is connected to the first member portion MMP 1 , and is spaced from the first sub-member portion SMMP 1 . The second sub-member portion SMMP 2 makes contact with a fourth sub-adhesive portion SALP 4 .

The window WD is on the first member MM 1 . The window WD may be flexible or rigid. The window WD includes a first window portion WDP 1 and a second window portion WDP 2 . The first window portion WDP 1 makes contact with the first adhesive layer AL 1 and does not make contact with the light blocking layers SP 1 and SP 2 .

The first window portion WDP 1 includes bending portions BP 1 and BP 2 and a non-bending portion NBP. The bending portions BP 1 and BP 2 may be bent. The non-bending portion NBP may be flat without being bent. The bending portions BP 1 and BP 2 include a first bending portion BP 1 and a second bending portion BP 2 . The first bending portion BP 1 is connected to the non-bending portion NBP. The first bending portion BP 1 is bent with respect to (e.g., about) the first bending axis BX 1 extending in the first direction DR 1 . The second bending portion BP 2 is connected to the non-bending portion NBP and spaced from the first bending portion BP 1 . The second bending portion BP 2 is bent with respect to (e.g., about) the second bending axis BX 2 extending in the first direction DR 1 . The second window portion WDP 2 makes contact with the light blocking layers SP 1 and SP 2 , and does not make contact with the first adhesive layer AL 1 .

The second window portion WDP 2 includes a first sub-window portion SWDP 1 and a second sub-window portion SWDP 2 . The first sub-window portion SWDP 1 is connected to the first window portion WDP 1 . The first sub-window portion SWDP 1 makes contact with the first light blocking layer SP 1 . The first sub-window portion SWDP 1 does not make contact with the first adhesive layer AL 1 . The second sub-window portion SWPD 2 is connected to the first window portion WDP 1 , and is spaced from the first sub-window portion SWDP 1 . The second sub-window portion SWDP 2 makes contact with the second light blocking layer SP 2 . The second sub-window portion SWDP 2 does not make contact with the first adhesive layer AL 1 .

The light blocking layers SP 1 and SP 2 are between the window WD and the first adhesive layer AL 1 . The light blocking layers SP 1 and SP 2 include the first light blocking layer SP 1 , and the second light blocking layer SP 2 spaced from the first light blocking layer SP 1 . The first light blocking layer SP 1 makes contact with the first sub-window portion SWDP 1 . The second light blocking layer SP 2 makes contact with the second sub-window portion SWDP 2 .

The first adhesive layer ALA is between the first member MM 1 and the window WD. The first adhesive layer AL 1 includes a first adhesive portion ALP 1 and a second adhesive portion ALP 2 . For instance, the first and second adhesive portions ALP 1 and ALP 2 are connected to each other, and extend along the second direction DR 2 . The first adhesive portion ALP 1 makes contact with (e.g., is adhered to) the first window portion WDP 1 and the first member portion MMP 1 . The first adhesive portion ALP 1 is attached to each of the first window portion WDP 1 and the first member portion MMP 1 to fix the first window portion WDP 1 and the first member portion MMP 1 to each other.

The first adhesive portion ALP 1 includes first sub-adhesive portions SSALP 1 and SSALP 2 and a second sub-adhesive portion SALP 2 . The first sub-adhesive portions SSALP 1 and SSALP 2 and the second sub-adhesive portion SALP 2 are connected to each other and generally extend along the second direction DR 2 . The first sub-adhesive portions SSALP 1 and SSALP 2 make contact with (e.g., are adhered to) respective ones of the bending portions BP 1 and BP 2 and respective ones of the first bending member portions SBMMP 1 and SBMMP 2 . The first sub-adhesive portions SSALP 1 and SSALP 2 are attached to the respective bending portions BP 1 and BP 2 and the respective first bending member portions SBMMP 1 and SBMMP 2 to fix the bending portions BP 1 and BP 2 and the first bending member portions SBMMP 1 and SBMMP 2 to respective ones of one another. The second sub-adhesive portion SALP 2 is connected to the first sub-adhesive portions SSALP 1 and SSALP 2 . The second sub-adhesive SALP 2 makes contact with the non-bending portion NBP and the first non-bending member portion NMMP 1 . The second sub-adhesive SALP 2 is attached to each of the non-bending portion NBP and the first non-bending member portion NMMP 1 to fix the non-bending portion NBP and the first non-bending member portion NMMP 1 to each other.

The first sub-adhesive portions SSALP 1 and SSALP 2 include a first bending adhesive portion SSALP 1 and a second bending adhesive SSALP 2 . The first bending adhesive portion SSALP 1 is connected to the second sub-adhesive portion SALP 2 . The first bending adhesive portion SSALP 1 makes contact with (e.g., is adhered to) the first bending portion BP 1 and the first sub-bending member portion SBMMP 1 . The first bending adhesive portion SSALP 1 is attached to each of the first bending portion BP 1 and the first sub-bending member portion SBMMP 1 to fix the first bending portion BP 1 and the first sub-bending member portion SBMMP 1 to each other. The second bending adhesive portion SSALP 2 is connected to the second sub-adhesive portion SALP 2 , and is spaced from the first bending adhesive portion SSALP 1 . The second bending adhesive portion SSALP 2 makes contact with (e.g., is adhered to) the second bending portion BP 2 and the second sub-bending member portion SBMMP 2 . The second bending adhesive portion SSALP 2 is attached to each of the second bending portion BP 2 and the second sub-bending member portion SBMMP 2 to fix the second bending portion BP 2 and the second sub-bending member portion SBMMP 2 to each other.

The second adhesive portion ALP 2 is connected to the first adhesive portion ALP 1 . The second adhesive portion ALP 2 makes contact with (e.g., is adhered to) the light blocking layers SP 1 and SP 2 and the second member portion MMP 2 . The second adhesive portion ALP 2 is attached to each of the light blocking layers SP 1 and SP 2 and the second member portion MMP 2 to fix the light blocking layers SP 1 and SP 2 and the second member portion MMP 2 to each other.

The second adhesive portion ALP 2 includes the third sub-adhesive portion SALP 3 and the fourth sub-adhesive portion SALP 4 . The third sub-adhesive portion SALP 3 is connected to the first adhesive portion ALP 1 . The third sub-adhesive portion SALP 3 makes contact with (e.g., is adhered to) the first light blocking layer SP 1 and the first sub-member portion SMMP 1 . The third sub-adhesive portion SALP 3 is attached to each of the first light blocking layer SP 1 and the first sub-member portion SMMP 1 to fix the first light blocking layer SP 1 and the first sub-member portion SMMP 1 to each other. The third sub-adhesive portion SALP 3 makes contact with one side surface of the first light blocking layer SP 1 .

The fourth sub-adhesive portion SALP 4 is connected to the first adhesive portion ALP 1 , and is spaced from the third sub-adhesive portion SALP 3 . The fourth sub-adhesive portion SALP 4 makes contact with (e.g., is adhered to) the second light blocking layer SP 2 and the second sub-member portion SMMP 2 . The fourth sub-adhesive portion SALP 4 is attached to each of the second light blocking layer SP 2 and the second sub-member portion SMMP 2 to fix the second light blocking layer SP 2 and the second sub-member portion SMMP 2 to each other. The fourth sub-adhesive portion SALP 4 makes contact (e.g., is adhered to) with one side surface of the second light blocking layer SP 2 .

Each of the first and second bending adhesive portions SSALP 1 and SSALP 2 have a modulus that is less than a modulus of each of the third and fourth sub-adhesive portions SALP 3 and SALP 4 . Each of the first and second bending adhesive portions SSALP 1 and SSALP 2 have a hardness that is less than a hardness of each of the third and fourth sub-adhesive portions SALP 3 and SALP 4 .

Each of the modulus of the first bending adhesive portion SSALP 1 and the modulus of the second bending adhesive portion SSALP 2 may be less than a modulus of the second adhesive portion ALP 2 . The hardness of the first bending adhesive portion SSALP 1 and the hardness of the second bending adhesive portion SSALP 2 may be less than a hardness of the second adhesive portion ALP 2 .

The modulus of the first bending adhesive portion SSALP 1 may be substantially the same as, or different from, the modulus of the second bending adhesive portion SSALP 2 . The hardness of the first bending adhesive portion SSALP 1 may be substantially the same as, or different from, the hardness of the second bending adhesive portion SSALP 2 .

The modulus of the third sub-adhesive portion SALP 3 may be substantially the same as, or different from, the modulus of the fourth sub-adhesive portion SALP 4 . The hardness of the third sub-adhesive portion SALP 3 may be substantially the same as, or different from, the hardness of the fourth sub-adhesive portion SALP 4 .

Each of the modulus of the third sub-adhesive portion SALP 3 and the modulus of the fourth sub-adhesive portion SALP 4 may be substantially the same as the modulus of the second adhesive portion ALP 2 , although embodiments of the present invention should not be limited thereto or thereby. For example, each of the modulus of the third sub-adhesive portion SALP 3 and the modulus of the fourth sub-adhesive portion SALP 4 may be greater than the modulus of the second adhesive portion ALP 2 . Each of the hardness of the third sub-adhesive portion SALP 3 and the hardness of the fourth sub-adhesive portion SALP 4 may be substantially the same as the hardness of the second adhesive portion ALP 2 , although the embodiments of the present invention should not be limited thereto or thereby. For example, each of the hardness of the third sub-adhesive portion SALP 3 and the hardness of the fourth sub-adhesive portion SALP 4 may be greater than the hardness of the second adhesive portion ALP 2 .

FIG. 3A is a perspective view showing a display device 10 according to an exemplary embodiment of the present disclosure, and FIG. 3B is a cross-sectional view showing the display device 10 shown in FIG. 3A .

Hereinafter, the display device 10 according to the present exemplary embodiment will be described in detail with reference to FIGS. 3A and 3B . In FIGS. 3A and 3B , features of the display device are primarily described that are different from those of the display device shown in FIGS. 1A and 1B and from those of the display device shown in FIGS. 2A and 2B .

Referring to FIGS. 3A and 3B , the display device 10 includes a first member MM 1 , a window WD, a light blocking layer SP, a first adhesive layer AL 1 , a second member MM 2 , and a second adhesive layer AL 2 . The first member MM 1 includes at least one of a polarizing plate, a display panel, and a touch screen panel. The first member MM 1 may be flexible or rigid.

The first member MM 1 includes a first member portion MMP 1 and a second member portion MMP 2 . The first member portion MMP 1 makes contact with (e.g., is adhered to) a first adhesive portion ALP 1 . The second member portion MMP 2 is connected to the first member portion MMP 1 . The second member portion MMP 2 makes contact with (e.g., is adhered to) a second adhesive portion ALP 2 . The first member portion MMP 1 includes a first bending member portion BMMP 1 and a first non-bending member portion NMMP 1 . The first bending member portion BMMP 1 is bent with respect to (e.g., about) a bending axis BX extending in a first direction DR 1 . The first bending member portion BMMP 1 makes contact with (e.g., is adhered to) a first sub-adhesive portion SALP 1 . The first non-bending member portion NMMP 1 is connected to the first bending member portion BMMP 1 . The first non-bending member portion NMMP 1 may be flat without being bent. The first non-bending member portion NMMP 1 makes contact with (e.g., is adhered to) a second sub-adhesive portion SALP 2 .

The window WD is disposed on the first member MM 1 . The window WD may be flexible or rigid. The window WD includes a first window portion WDP 1 and a second window portion WDP 2 . The first window portion WDP 1 makes contact with (e.g., is adhered to) the first adhesive layer AL 1 and does not make contact with the light blocking layer SP. The first window portion WDP 1 includes a bending portion BP and a non-bending portion NBP. The bending portion BP is bent with respect to (e.g., about) the bending axis BX extending in the first direction DR 1 . The non-bending portion NBP may be flat without being bent. The second window portion WDP 2 makes contact with the light blocking layer SP, and does not make contact with the first adhesive layer AL 1 .

The light blocking layer SP is between the window WD and the first adhesive layer AL 1 . The light blocking layer SP makes contact with the second window portion WDP 2 . The light blocking layer SP does not make contact with the first window portion WDP 1 .

The first adhesive layer AL 1 is between the first member MM 1 and the window WD. The first adhesive layer AL 1 includes the first adhesive portion ALP 1 and the second adhesive portion ALP 2 . The first adhesive portion ALP 1 makes contact with (e.g., is adhered to) the first window portion WDP 1 and the first member portion MMP 1 . The first adhesive portion ALP 1 is attached to each of the first window portion WDP 1 and the first member portion MMP 1 to fix the first window portion WDP 1 and the first member portion MMP 1 to each other. The second adhesive portion ALP 2 makes contact with (e.g., is adhered to) the light blocking layer SP and the second member portion MMP 2 . The second adhesive portion ALP 2 is attached to each of the light blocking layer SP and the second member portion MMP 2 to fix the light blocking layer SP and the second member portion MMP 2 to each other.

The first adhesive portion ALP 1 includes a first sub-adhesive portion SALP 1 and a second sub-adhesive portion SALP 2 . The first sub-adhesive portion SALP 1 makes contact with (e.g., is adhered to) the bending portion BP and the first bending member portion BMMP 1 . The first sub-adhesive portion SALP 1 is attached to the bending portion BP and the first bending member portion BMMP 1 to fix the bending portion BP and the first bending member portion BMMP 1 to each other. The first sub-adhesive portion SALP 1 makes contact with one side surface of the light blocking layer SP.

The second adhesive portion ALP 2 is connected to the first sub-adhesive portion SALP 1 . The second sub-adhesive portion SALP 2 makes contact with (e.g., is adhered to) the non-bending portion NBP and the first non-bending member portion NMMP 1 . The second sub-adhesive portion SALP 2 is attached to the non-bending portion NBP and the first non-bending member portion NMMP 1 to fix the non-bending portion NBP and the first non-bending member portion NMMP 1 to each other.

The first sub-adhesive portion SALP 1 has a modulus that is less than a modulus of the second sub-adhesive portion SALP 2 and that is less than a modulus of the second adhesive portion ALP 2 . The first sub-adhesive portion SALP 1 has a hardness that is less than a hardness of the second sub-adhesive portion SALP 2 and that is less than a hardness of the second adhesive portion ALP 2 .

The modulus of the second sub-adhesive portion SALP 2 may be substantially the same as the modulus of the second adhesive portion ALP 2 . The hardness of the second sub-adhesive portion SALP 2 may be substantially the same as the hardness of the second adhesive portion ALP 2 , although embodiments of the present invention should not be limited thereto or thereby. For example, the modulus of the second sub-adhesive portion SALP 2 may be less than the modulus of the second adhesive portion ALP 2 . Further, the hardness of the second sub-adhesive portion SALP 2 may be less than the hardness of the second adhesive portion ALP 2 .

The second member MM 2 is under the first member MM 1 . The second member MM 2 may be different from the first member MM 1 . The second member MM 2 may include at least one of the polarization plate, the display panel, and the touch screen panel. The second member MM 2 may be flexible or rigid.

The second member MM 2 includes a third member portion MMP 3 and a fourth member portion MMP 4 . The fourth member portion MMP 4 is connected to the third member portion MMP 3 . The fourth member portion MMP 4 makes contact with (e.g., is adhered to) the fourth adhesive portion ALP 4 . The third member portion MMP 3 includes a second bending member portion BMMP 2 and a second non-bending member portion NMMP 2 . The second bending member portion BMMP 2 is bent with respect to (e.g., about) the bending axis BX extending in the first direction DR 1 . The second bending member portion BMMP 2 makes contact with (e.g., is adhered to) a fifth sub-adhesive portion SALP 5 . The second non-bending member portion NMMP 2 is connected to the second bending member portion BMMP 2 . The second non-bending member portion NMMP 2 may be flat without being bent. The second non-bending member portion NMMP 2 makes contact with (e.g., is adhered to) a sixth sub-adhesive portion SALP 6 .

The second adhesive layer AL 2 is between the first member MM 1 and the second member MM 2 . The second adhesive layer AL 2 is attached to each of the first member MM 1 and the second member MM 2 to fix the first member MM 1 and the second member MM 2 to each other. The second adhesive layer AL 2 includes at least one of an acrylic-based compound and an acrylic-based copolymer. The second adhesive layer AL 2 includes a UV curing agent.

The second adhesive layer AL 2 includes the third adhesive portion ALP 3 and the fourth adhesive portion ALP 4 . The third adhesive portion ALP 3 makes contact with (e.g., is adhered to) the first member portion MMP 1 and a third member portion MMP 3 . The third adhesive portion ALP 3 is attached to each of the first member portion MMP 1 and the third member portion MMP 3 to fix the first member portion MMP 1 and the third member portion MMP 3 . The fourth adhesive portion ALP 4 is connected to the third adhesive portion ALP 3 . The fourth adhesive portion ALP 4 makes contact with (e.g., is adhered to) the second member portion MMP 2 and the fourth member portion MMP 4 . The fourth adhesive portion ALP 4 is attached to each of the second member portion MMP 2 and the fourth member portion MMP 4 to fix the second member portion MMP 2 and the fourth member portion MMP 4 to each other.

The third adhesive portion ALP 3 includes the fifth sub-adhesive portion SALP 5 and the sixth sub-adhesive portion SALP 6 . The fifth sub-adhesive portion SALP 5 makes contact with (e.g., is adhered to) the first bending member portion BMMP 1 and the second bending member portion BMMP 2 . The fifth sub-adhesive portion SALP 5 is attached to each of the first bending member portion BMMP 1 and the second bending member portion BMMP 2 to fix the first bending member portion BMMP 1 and the second bending member portion BMMP 2 to each other. The fifth sub-adhesive portion SALP 5 makes contact with (e.g., is adhered to) one side surface of the fourth adhesive portion ALP 4 .

The sixth sub-adhesive portion SALP 6 is connected to the fifth sub-adhesive portion SALP 5 . The sixth sub-adhesive portion SALP 6 makes contact with (e.g., is adhered to) the first non-bending member portion NMMP 1 and the second non-bending member portion NMMP 2 . The sixth sub-adhesive portion SALP 6 is attached to each of the first non-bending member portion NMMP 1 and the second non-bending member portion NMMP 2 to fix the first non-bending member portion NMMP 1 and the second non-bending member portion NMMP 2 to each other.

The fifth sub-adhesive portion SALP 5 has a modulus that is less than each of a modulus of the sixth sub-adhesive portion SALP 6 and a modulus of the fourth adhesive portion ALP 4 . The fifth sub-adhesive portion SALP 5 has a hardness that is less than each of a hardness of the sixth sub-adhesive portion SALP 6 and a hardness of the fourth adhesive portion ALP 4 .

The modulus of the fifth sub-adhesive portion SALP 5 may be substantially the same as the modulus of the first sub-adhesive portion SALP 1 . The hardness of the fifth sub-adhesive portion SALP 5 may be substantially the same as the hardness of the first sub-adhesive portion SALP 1 , although embodiments of the present invention should not be limited thereto or thereby. For example, the modulus of the fifth sub-adhesive portion SALP 5 may be different from the modulus of the first sub-adhesive portion SALP 1 . Further, the hardness of the fifth sub-adhesive portion SALP 5 may be different from the hardness of the first sub-adhesive portion SALP 1 .

The modulus of the sixth sub-adhesive portion SALP 6 may be substantially the same as the modulus of the fourth adhesive portion ALP 4 . The hardness of the sixth sub-adhesive portion SALP 6 may be substantially the same as the hardness of the fourth adhesive portion ALP 4 , although embodiments of the present invention should not be limited thereto or thereby. For example, the modulus of the sixth sub-adhesive portion SALP 6 may be less than the modulus of the fourth adhesive portion ALP 4 . Further, the hardness of the sixth sub-adhesive portion SALP 6 may be less than the hardness of the fourth adhesive portion ALP 4 .

The modulus of the sixth sub-adhesive portion SALP 6 may be substantially the same as the modulus of the second sub-adhesive portion SALP 2 . The hardness of the sixth sub-adhesive portion SALP 6 may be substantially the same as the hardness of the second sub-adhesive portion SALP 2 , although embodiments of the present invention should not be limited thereto or thereby. For example, the modulus of the sixth sub-adhesive portion SALP 6 may be different from the modulus of the second sub-adhesive portion SALP 2 . Further, the hardness of the sixth sub-adhesive portion SALP 6 may be different from the hardness of the second sub-adhesive portion SALP 2 .

In general, a first adhesive layer included in a conventional display device has only one modulus (e.g., a single modulus throughout the layer). Accordingly, the first adhesive layer may not be sufficient for attaching to a step difference portion between a window and a light blocking layer. As a result, the first adhesive layer may be gradually spaced from (e.g., separated from) the step difference portion when the conventional display device is bent.

The first adhesive layer included in the display device according to the exemplary embodiments of the present disclosure has a plurality of moduli. In the first adhesive layer included in the display device according to the exemplary embodiments of the present disclosure, the modulus of the first sub-adhesive portion, which makes contact with the bending portion of the window and the one side surface of the light blocking layer, is less than each of the modulus of the second sub-adhesive portion making contact with the non-bending portion of the window, and the modulus of the second adhesive portion making contact with the light blocking layer. Because the first sub-adhesive portion has flexibility that is greater than that of each of the second sub-adhesive portion and the second adhesive portion, the first adhesive layer may be securely attached to the step difference portion caused by the window and the light blocking layer, and thus the first adhesive layer may be prevented or substantially prevented from being spaced from the step difference portion even though the display device is bent. Therefore, the display device according to the exemplary embodiments of the present disclosure may have improved (e.g., increased) durability.

Hereinafter, a method of manufacturing the display device will be described in detail.

FIG. 4 is a flow diagram showing a method of manufacturing a display device according to an exemplary embodiment of the present disclosure, and FIGS. 5A to 5E are cross-sectional views showing processes of the manufacturing method of the display device according to an exemplary embodiment of the present disclosure.

Referring to FIGS. 4 and 5A to 5E , the manufacturing method of the display device includes preparing the first adhesive layer AL 1 , which includes the first adhesive portion ALP 1 including the first sub-adhesive portion SALP 1 , and the second sub-adhesive portion SALP 2 (S 100 ), curing the first adhesive layer AL 1 such that the hardness of the first sub-adhesive portion SALP 1 is less than the hardness of each of the second sub-adhesive portion SALP 2 and the second adhesive portion ALP 2 (S 200 ), attaching the first adhesive layer AL 1 to the light blocking layer SP and the window WD (S 300 ), and attaching the first adhesive layer AL 1 to the first member MM 1 (S 400 ).

Referring to FIGS. 4 and 5A , the first adhesive layer AL 1 is prepared (S 100 ). The first adhesive layer AL 1 includes the first adhesive portion ALP 1 and the second adhesive portion ALP 2 . The first adhesive portion ALP 1 includes the first sub-adhesive portion SALP 1 and the second sub-adhesive portion SALP 2 . The first adhesive layer AL 1 includes at least one of an acrylic-based compound and an acrylic-based copolymer, although the first adhesive layer AL 1 should not be limited thereto or thereby. For example, the first adhesive layer AL 1 may include the UV curing agent.

Referring to FIGS. 4, 5B, and 5C , the first adhesive layer AL 1 is cured such that the hardness of the first sub-adhesive portion SALP 1 is less than the hardness of each of the second sub-adhesive portion SALP 2 and the second adhesive portion ALP 2 (S 200 ). The curing of the first adhesive layer AL 1 (S 200 ) includes providing a mask above the first adhesive layer AL 1 and applying a UV light to the first adhesive layer AL 1 using the mask. The curing of the first adhesive layer AL 1 ( 8200 ) may be performed before or after the attaching of the first adhesive layer AL 1 to the window WD.

Referring to FIGS. 4 and 5B , a first mask MSK 1 is above the first adhesive layer AL 1 and the UV light is provided to the first adhesive layer AL 1 through the first mask MSK 1 . The first adhesive layer AL 1 is cured using the first mask MSK 1 such that the hardness of the first sub-adhesive portion SALP 1 is less than the hardness of each of the second sub-adhesive portion SALP 2 and the second adhesive portion ALP 2 . The hardness of the second sub-adhesive portion SALP 2 may be substantially the same as the hardness of the second adhesive portion ALP 2 . The modulus of the first sub-adhesive portion SALP 1 may be less than the modulus of each of the second sub-adhesive portion SALP 2 and the second adhesive portion ALP 2 . The modulus of the second sub-adhesive portion SALP 2 may be substantially the same as the modulus of the second adhesive portion ALP 2 .

Referring to FIGS. 4 and 5C , a second mask MSK 2 is disposed above the first adhesive layer AL 1 and the UV light is provided to (e.g., is applied to or shone upon) the first adhesive layer AL 1 through the second mask MSK 2 . The first adhesive layer AL 1 is cured using the second mask MSK 2 such that the hardness of the first sub-adhesive portion SALP 1 is less than the hardness of each of the second sub-adhesive portion SALP 2 and the second adhesive portion ALP 2 . The hardness of the second sub-adhesive portion SALP 2 may be less than the hardness of the second adhesive portion ALP 2 . The modulus of the first sub-adhesive portion SALP 1 may be less than the modulus of each of the second sub-adhesive portion SALP 2 and the second adhesive portion ALP 2 . The modulus of the second sub-adhesive portion SALP 2 may be less than the modulus of the second adhesive portion ALP 2 .

Referring to FIGS. 4 and 5D , the first adhesive layer AL 1 is attached to the light blocking layer SP and the window WD (S 300 ). The window WD includes the first window portion WDP 1 and the second window portion WDP 2 . The first window portion WDP 1 includes the bending portion BP and the non-bending portion NBP. The second window portion WDP 2 makes contact with the light blocking layer SP. The second window portion WDP 2 is connected to the first window portion WDP 1 . The second window portion WDP 2 is spaced from the non-bending portion NBP, and is connected to the bending portion BP. The attaching of the first adhesive layer AL 1 to the light blocking layer SP and the window WD (S 300 ) is performed such that the first sub-adhesive portion SALP 1 is attached to the bending portion BP, the second sub-adhesive portion SALP 2 is attached to the non-bending portion NBP, and the second adhesive portion ALP 2 is attached to the light blocking layer SP.

Referring to FIGS. 5 and 5E , the first adhesive layer AL 1 is attached to the first member MM 1 (S 400 ). The first member MM 1 includes the first member portion MMP 1 and the second member portion MMP 2 . The first member portion MMP 1 includes the first bending member portion BMMP 1 and the first non-bending member portion NMMP 1 . The second member portion MMP 2 is connected to the first member portion MMP 1 . The second member portion MMP 2 makes contact with (e.g., is adhered to) the second adhesive portion ALP 2 . The attaching of the first adhesive layer AL 1 to the first member MM 1 (S 400 ) may include attaching the first adhesive portion ALP 1 to the first member portion MMP 1 , and may include attaching the second adhesive portion ALP 2 to the second member portion MMP 2 . The attaching of the first adhesive layer AL 1 to the first member MM 1 (S 400 ) may include attaching the first sub-adhesive portion SALP 1 to the first bending member portion BMMP 1 , and may include attaching the second sub-adhesive portion SALP 2 to the first non-bending member portion NMMP 1 .

The attaching of the first adhesive layer AL 1 to the light blocking layer SP and the window WD (S 300 ) and the attaching of the first adhesive layer AL 1 and the first member MM 1 (S 400 ) may be concurrently (e.g., substantially simultaneously) performed, although embodiments of the present invention should not be limited thereto or thereby. For example, the attaching of the first adhesive layer AL 1 and the first member MM 1 (S 400 ) may be performed after the attaching of the first adhesive layer AL 1 to the light blocking layer SP and the window WD (S 300 ) is performed, and the attaching of the first adhesive layer AL 1 to the light blocking layer SP and the window WD (S 300 ) may be performed after the attaching of the first adhesive layer AL 1 and the first member MM 1 (S 400 ) is performed.

In general, the first adhesive layer included in the conventional display device has only one modulus. Accordingly, the first adhesive layer may not be sufficient for attaching to the step difference portion between the window and the light blocking layer. As a result, the first adhesive layer may be gradually spaced from (e.g., separated from) the step difference portion when the conventional display device is bent.

The first adhesive layer included in the display device manufactured by the manufacturing method according to the exemplary embodiments of the present disclosure has the moduli. In the first adhesive layer included in the display device according to the exemplary embodiments of the present disclosure, the modulus of the first sub-adhesive portion making contact with the bending portion of the window and the one side surface of the light blocking layer is less than each of the modulus of the second sub-adhesive portion making contact with the non-bending portion of the window and the modulus of the second adhesive portion making contact with the light blocking layer. Because the first sub-adhesive portion has flexibility greater than that of each of the second sub-adhesive portion and the second adhesive portion, the first adhesive layer may be securely attached to the step difference portion caused by the window and the light blocking layer, and thus the first adhesive layer may be prevented or substantially prevented from being spaced from the step difference portion even though the display device is bent. Therefore, the display device according to the exemplary embodiments of the present disclosure may have improved (e.g., increased) durability.

It will be understood that, although the terms “first”, “second”, “third”, etc., may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section, without departing from the spirit and scope of the inventive concept.

Spatially relative terms, such as “beneath”, “below”, “lower”, “under”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or in operation, in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” or “under” other elements or features would then be oriented “above” the other elements or features. Thus, the example terms “below” and “under” can encompass both an orientation of above and below. The device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly. In addition, it will also be understood that when a layer is referred to as being “between” two layers, it can be the only layer between the two layers, or one or more intervening layers may also be present.

The terminology used herein is for the purpose of describing particular embodiments and is not intended to be limiting of the inventive concept. As used herein, the singular forms “a” and “an” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “include,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Expressions such as “at least one of,” when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list. Further, the use of “may” when describing embodiments of the inventive concept refers to “one or more embodiments of the inventive concept.” Also, the term “exemplary” is intended to refer to an example or illustration.

It will be understood that when an element or layer is referred to as being “on”, “connected to”, or “coupled to” another element or layer, it can be directly on, connected to, or coupled to the other element or layer, or one or more intervening elements or layers may be present. When an element or layer is referred to as being “directly on,” “directly connected to”, or “directly coupled to” another element or layer, there are no intervening elements or layers present.

As used herein, the term “substantially,” “about,” and similar terms are used as terms of approximation and not as terms of degree, and are intended to account for the inherent variations in measured or calculated values that would be recognized by those of ordinary skill in the art.

As used herein, the terms “use,” “using,” and “used” may be considered synonymous with the terms “utilize,” “utilizing,” and “utilized,” respectively.

Although the exemplary embodiments of the present invention have been described, it is understood that the present invention should not be limited to these exemplary embodiments but various suitable changes and modifications can be made by one ordinary skilled in the art within the spirit and scope of the present invention as defined by the appended claims and equivalents thereof.