U.S. patent application number 14/317988 was filed with the patent office on 2015-01-01 for curved display panel manufacturing method.
The applicant listed for this patent is TOVIS CO., LTD.. Invention is credited to Yong Beom KIM, Woon Yong PARK.
Application Number | 20150000823 14/317988 |
Document ID | / |
Family ID | 52114449 |
Filed Date | 2015-01-01 |
United States Patent
Application |
20150000823 |
Kind Code |
A1 |
KIM; Yong Beom ; et
al. |
January 1, 2015 |
CURVED DISPLAY PANEL MANUFACTURING METHOD
Abstract
A curved display panel manufacturing method is provided. The
curved display panel manufacturing method in which a display panel
in a desired curved shape is manufactured using a prefabricated
flat liquid crystal panel including a lower substrate and an upper
substrate formed of glass and opposite each other, each of the
lower substrate and an upper substrate being provided with a
polarizing plate, and a liquid crystal layer formed between the
lower substrate and the upper substrate, includes separating the
polarizing plates from the lower substrate and the upper substrate,
removing the outer surface of the liquid crystal panel to reduce
the lower substrate and the upper substrate from which the
polarizing plates are separated to a designated thickness, and
bending the liquid crystal panel having the removed outer surface
in a desired curved shape.
Inventors: |
KIM; Yong Beom; (Incheon,
KR) ; PARK; Woon Yong; (Suwon-si, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TOVIS CO., LTD. |
Incheon |
|
KR |
|
|
Family ID: |
52114449 |
Appl. No.: |
14/317988 |
Filed: |
June 27, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13394585 |
Mar 7, 2012 |
|
|
|
PCT/KR2010/005913 |
Sep 1, 2010 |
|
|
|
14317988 |
|
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Current U.S.
Class: |
156/80 ;
156/213 |
Current CPC
Class: |
B29K 2709/08 20130101;
B32B 17/064 20130101; B32B 43/006 20130101; B32B 2307/412 20130101;
G02F 2001/133302 20130101; G02F 1/1333 20130101; B32B 37/12
20130101; B29C 45/1671 20130101; G02F 1/133528 20130101; B29K
2995/0034 20130101; B32B 2307/42 20130101; B32B 37/18 20130101;
Y10T 156/1028 20150115; Y10T 156/103 20150115; B32B 2310/0831
20130101; B29K 2995/0026 20130101; B29L 2031/3475 20130101; B32B
2457/202 20130101; B32B 2037/1253 20130101; B32B 2307/40 20130101;
B32B 38/1866 20130101; B32B 37/1284 20130101 |
Class at
Publication: |
156/80 ;
156/213 |
International
Class: |
B32B 38/18 20060101
B32B038/18; B32B 37/18 20060101 B32B037/18; B32B 43/00 20060101
B32B043/00; B32B 37/12 20060101 B32B037/12; B32B 37/14 20060101
B32B037/14; B32B 38/10 20060101 B32B038/10 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 18, 2009 |
KR |
10-2009-0088292 |
Claims
1. A curved display panel manufacturing method in which a display
panel in a desired curved shape is manufactured using a
prefabricated flat liquid crystal panel including a lower substrate
and an upper substrate formed of glass and opposite each other,
each of the lower substrate and an upper substrate being provided
with a polarizing plate, and a liquid crystal layer formed between
the lower substrate and the upper substrate, comprising: separating
the polarizing plates from the lower substrate and the upper
substrate; removing the outer surface of the liquid crystal panel
to reduce the lower substrate and the upper substrate from which
the polarizing plates are separated to a designated thickness;
bending the liquid crystal panel having the removed outer surface
in a desired curved shape; and attaching prefabricated transparent
substrates bent in the same curved shape as the desired curved
shape to the liquid crystal panel bent in the desired curved shape
using an adhesive so as to maintain the curved shape of the liquid
crystal panel.
2. The curved display panel manufacturing method according to claim
1, further comprising re-attaching the separated polarizing plates
to the lower substrate and the upper substrate, after the bending
of the liquid crystal panel having the removed outer surface in the
desired curved shape.
3. The curved display panel manufacturing method according to claim
1, wherein the liquid crystal panel further includes a tab
electrically connected to the liquid crystal panel, wherein the
curved display panel manufacturing method further comprises:
separating the tab from the liquid crystal panel before the removal
of the outer surface of the liquid crystal panel; and re-attaching
the separated tab to the liquid crystal panel after the attachment
of the transparent substrates to the liquid crystal panel.
4. The curved display panel manufacturing method according to claim
1, wherein the removal of the outer surface of the liquid crystal
panel to reduce the lower substrate and the upper substrate from
which the polarizing plates are separated to a designated thickness
includes masking parts of the upper substrate or the lower
substrate where protrusions separating the transparent substrates
from the lower substrate or the upper substrate will be formed with
masking members preventing removal of the outer surface of the
liquid crystal panel so as to form the protrusions.
5. The curved display panel manufacturing method according to claim
1, further comprising attaching separation members having a random
thickness to the lower substrate or the upper substrate so as to
form protrusions separating the transparent substrates from the
lower substrate or the upper substrate, before the attachment of
the transparent substrates to the liquid crystal panel bent in the
desired curved shape so as to maintain the curved shape of the
liquid crystal panel.
6. The curved display panel manufacturing method according to claim
4, wherein the protrusions are formed at both ends of the lower
substrate or the upper substrate.
7. The curved display panel manufacturing method according to claim
5, wherein the protrusions are formed at both ends of the lower
substrate or the upper substrate.
8. The curved display panel manufacturing method according to claim
4, further comprising injecting a liquid transparent polymer into
spaces between the liquid crystal panel and the transparent
substrates, attached to the liquid crystal panel while being
separated from the liquid crystal panel by the protrusions, and
then hardening the injected liquid transparent polymer, after the
attachment of the transparent substrates to the liquid crystal
panel bent in the desired curved shape so as to maintain the curved
shape of the liquid crystal panel.
9. The curved display panel manufacturing method according to claim
5, further comprising injecting a liquid transparent polymer into
spaces between the liquid crystal panel and the transparent
substrates, attached to the liquid crystal panel while being
separated from the liquid crystal panel by the protrusions, and
then hardening the injected liquid transparent polymer, after the
attachment of the transparent substrates to the liquid crystal
panel bent in the desired curved shape so as to maintain the curved
shape of the liquid crystal panel.
10. The curved display panel manufacturing method according to
claim 1, wherein the separation of the polarizing plates from the
lower substrate and the upper substrate includes cooling the liquid
crystal panel to a sub-zero temperature so that an adhesive
attaching the polarizing plates to the lower substrate and the
upper substrate loses adhesive force.
11. A curved display panel manufacturing method in which a display
panel in a desired curved shape is manufactured using a
prefabricated flat liquid crystal panel including a lower substrate
and an upper substrate formed of glass and opposite each other,
each of the lower substrate and an upper substrate being provided
with a polarizing plate, and a liquid crystal layer formed between
the lower substrate and the upper substrate, comprising: separating
the polarizing plates from the lower substrate and the upper
substrate; removing the outer surface of the liquid crystal panel
to reduce the lower substrate and the upper substrate from which
the polarizing plates are separated to a designated thickness;
bending the liquid crystal panel having the removed outer surface
in a desired curved shape; re-attaching the separated polarizing
plates to the lower substrate and the upper substrate; and forming
transparent polymer layers on the outer surface of the liquid
crystal panel by loading the liquid crystal panel into a mold set
formed in the same curved shape as the desired curved shape,
injecting a liquid transparent polymer into the mold set, and
hardening the liquid transparent polymer, so as to maintain the
curved shape of the liquid crystal panel.
12. The curved display panel manufacturing method according to
claim 9, further comprising setting the thickness of the
transparent polymer layers to be formed within the mold set, before
the formation of the transparent polymer layers on the outer
surface of the liquid crystal panel.
13. A curved display panel manufacturing method in which a display
panel in a desired curved shape is manufactured using a
prefabricated flat liquid crystal panel including a lower substrate
and an upper substrate formed of glass and opposite each other,
each of the lower substrate and an upper substrate being provided
with a polarizing plate, and a liquid crystal layer formed between
the lower substrate and the upper substrate, comprising: separating
the polarizing plates from the lower substrate and the upper
substrate; removing the outer surface of the liquid crystal panel
to reduce the lower substrate and the upper substrate from which
the polarizing plates are separated to a designated thickness;
bending the liquid crystal panel having the removed outer surface
in a desired curved shape; forming polarizing patterns on
prefabricated transparent substrates bent in the same curved shape
as the desired curved shape; and attaching the prefabricated
transparent substrates to the outer surface of the liquid crystal
panel bent in the desired curved shape so as to maintain the curved
shape of the liquid crystal panel.
Description
REFERENCE TO RELATED APPLICATION
[0001] This application is continuation-in-part application of
application Ser. No. 13/394,585 filed on Mar. 7, 2012, the
disclosure of which is incorporated by reference in its
entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a display panel
manufacturing method for manufacturing a display panel in a curved
shape.
[0004] 2. Description of the Related Art
[0005] As display technology advances, various kinds of display
devices are being developed and used. From among these display
devices, there is a liquid crystal display device to display an
image using liquid crystals.
[0006] A liquid crystal panel of a general liquid crystal display
(LCD) includes two substrates and a liquid crystal layer having
dielectric anisotropy interposed between the two substrates. The
liquid crystal panel applies an electric field to the liquid
crystal layer and adjusts an intensity of the electric field to
adjust transmittance of light passing through the liquid crystal
layer, thereby obtaining a desired image. Such an LCD is a
representative one of flat panel displays (FPDs) which are handy to
carry. From among various LCDs, a TFT-LCD using thin film
transistors (TFTs) as switching elements is mainly used.
[0007] From among the two substrates of the liquid crystal panel
which are opposite each other, a plurality of display signal lines,
i.e., gate lines and data lines, a plurality of thin film
transistors and pixel electrodes are formed on the lower substrate,
and color filters and a common electrode are formed on the upper
substrate. Further, polarizing plates are attached to the outer
surfaces of the two glass substrates.
[0008] Such a liquid crystal panel is generally manufactured in a
flat shape. Therefore, if a curved display is required, the general
flat liquid crystal panel may not be used.
[0009] In order to solve such a problem, a flexible liquid crystal
panel which employs substrates formed of a flexible material rather
than glass substrates used in the conventional liquid crystal panel
so as to be curved if external force is applied to the flexible
liquid crystal panel has been developed.
[0010] However, the above conventional flexible liquid crystal
panel has a difficult manufacturing process and high manufacturing
costs.
SUMMARY OF THE INVENTION
[0011] Therefore, the present invention has been made in view of
the above problems, and it is an object of the present invention to
provide a curved display panel manufacturing method for simply
manufacturing a display panel in a bent shape using a general flat
liquid crystal panel including polarizing plates and glass
substrates to which electronic circuits necessary for driving are
attached.
[0012] In accordance with an aspect of the present invention, the
above and other objects can be accomplished by the provision of a
curved display panel manufacturing method in which a display panel
in a desired curved shape is manufactured using a prefabricated
flat liquid crystal panel including a lower substrate and an upper
substrate formed of glass and opposite each other, each of the
lower substrate and an upper substrate being provided with a
polarizing plate, and a liquid crystal layer formed between the
lower substrate and the upper substrate, including separating the
polarizing plates from the lower substrate and the upper substrate,
removing the outer surface of the liquid crystal panel to reduce
the lower substrate and the upper substrate from which the
polarizing plates are separated to a designated thickness, bending
the liquid crystal panel having the removed outer surface in a
desired curved shape, and attaching prefabricated transparent
substrates bent in the same curved shape as the desired curved
shape to the liquid crystal panel bent in the desired curved shape
using an adhesive so as to maintain the curved shape of the liquid
crystal panel.
[0013] The curved display panel manufacturing method may further
include re-attaching the separated polarizing plates to the lower
substrate and the upper substrate, after the bending of the liquid
crystal panel having the removed outer surface in the desired
curved shape.
[0014] The liquid crystal panel may further include a tab
electrically connected to the liquid crystal panel, and the curved
display panel manufacturing method may further include separating
the tab from the liquid crystal panel before the removal of the
outer surface of the liquid crystal panel and re-attaching the
separated tab to the liquid crystal panel after the attachment of
the transparent substrates to the liquid crystal panel.
[0015] The removal of the outer surface of the liquid crystal panel
to reduce the lower substrate and the upper substrate from which
the polarizing plates are separated to a designated thickness may
include masking parts of the upper substrate or the lower substrate
where protrusions separating the transparent substrates from the
lower substrate or the upper substrate will be formed with masking
members preventing removal of the outer surface of the liquid
crystal panel so as to form the protrusions.
[0016] The curved display panel manufacturing method may further
include attaching separation members having a random thickness to
the lower substrate or the upper substrate so as to form
protrusions separating the transparent substrates from the lower
substrate or the upper substrate, before the attachment of the
transparent substrates to the liquid crystal panel bent in the
desired curved shape so as to maintain the curved shape of the
liquid crystal panel.
[0017] The protrusions may be formed at both ends of the lower
substrate or the upper substrate.
[0018] The curved display panel manufacturing method may further
include injecting a liquid transparent polymer into spaces between
the liquid crystal panel and the transparent substrates, attached
to the liquid crystal panel while being separated from the liquid
crystal panel by the protrusions, and then hardening the injected
liquid transparent polymer, after the attachment of the transparent
substrates to the liquid crystal panel bent in the desired curved
shape so as to maintain the curved shape of the liquid crystal
panel.
[0019] The separation of the polarizing plates from the lower
substrate and the upper substrate may include cooling the liquid
crystal panel to a sub-zero temperature so that an adhesive
attaching the polarizing plates to the lower substrate and the
upper substrate loses adhesive force.
[0020] In accordance with another aspect of the present invention,
there is provided a curved display panel manufacturing method in
which a display panel in a desired curved shape is manufactured
using a prefabricated flat liquid crystal panel including a lower
substrate and an upper substrate formed of glass and opposite each
other, each of the lower substrate and an upper substrate being
provided with a polarizing plate, and a liquid crystal layer formed
between the lower substrate and the upper substrate, including
separating the polarizing plates from the lower substrate and the
upper substrate, removing the outer surface of the liquid crystal
panel to reduce the lower substrate and the upper substrate from
which the polarizing plates are separated to a designated
thickness, bending the liquid crystal panel having the removed
outer surface in a desired curved shape, re-attaching the separated
polarizing plates to the lower substrate and the upper substrate,
and forming transparent polymer layers on the outer surface of the
liquid crystal panel by loading the liquid crystal panel into a
mold set formed in the same curved shape as the desired curved
shape, injecting a liquid transparent polymer into the mold set,
and hardening the liquid transparent polymer, so as to maintain the
curved shape of the liquid crystal panel.
[0021] The curved display panel manufacturing method may further
include setting the thickness of the transparent polymer layers to
be formed within the mold set, before the formation of the
transparent polymer layers on the outer surface of the liquid
crystal panel.
[0022] In accordance with yet another aspect of the present
invention, there is provided a curved display panel manufacturing
method in which a display panel in a desired curved shape is
manufactured using a prefabricated flat liquid crystal panel
including a lower substrate and an upper substrate formed of glass
and opposite each other, each of the lower substrate and an upper
substrate being provided with a polarizing plate, and a liquid
crystal layer formed between the lower substrate and the upper
substrate, including separating the polarizing plates from the
lower substrate and the upper substrate, removing the outer surface
of the liquid crystal panel to reduce the lower substrate and the
upper substrate from which the polarizing plates are separated to a
designated thickness, bending the liquid crystal panel having the
removed outer surface in a desired curved shape, forming polarizing
patterns on prefabricated transparent substrates bent in the same
curved shape as the desired curved shape, and attaching the
prefabricated transparent substrates to the outer surface of the
liquid crystal panel bent in the desired curved shape so as to
maintain the curved shape of the liquid crystal panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The above and other objects, features and other advantages
of the present invention will be more clearly understood from the
following detailed description taken in conjunction with the
accompanying drawings, in which:
[0024] FIG. 1 is a sectional view illustrating a general liquid
crystal panel to which a curved display panel manufacturing method
in accordance with the present invention is applied;
[0025] FIGS. 2A to 2F are schematic views illustrating a curved
display panel manufacturing method in accordance with one
embodiment of the present invention;
[0026] FIGS. 3A and 3B are views protrusions formed on a lower
substrate and an upper substrate in the curved display panel
manufacturing method in accordance with the embodiment of the
present invention;
[0027] FIG. 4 is a sectional view of a display panel manufactured
using the lower substrate and the upper substrate provided with the
protrusions of FIG. 3; and
[0028] FIGS. 5A to 5C are schematic views illustrating a curved
display panel manufacturing method in accordance with another
embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Hereinafter, embodiments of the present invention will be
described in more detail with reference to the accompanying
drawings.
[0030] In the drawings, the thickness of each of several layers and
regions is exaggerated for convenience of description and clarity.
Wherever possible, the same reference numbers will be used
throughout the drawings to refer to the same or like parts. It will
be understood that when an element is referred to as being "on" or
"under" another element, it can be directly on/under the element,
and one or more intervening elements may also be present. However,
when an element is referred to as being directly "on" or "under"
another element, one or more intervening elements are not
present.
[0031] Further, in the specification, the terms "two substrates",
"lower substrate" and "upper substrate" include the concept of one
or both of a lower substrate and an upper substrate.
[0032] A display panel manufacturing method in accordance with one
embodiment of the present invention is a method for manufacturing a
display panel in a curved shape using a general liquid crystal
panel.
[0033] Here, the general liquid crystal panel means a ready-made
liquid crystal panel.
[0034] With reference to FIG. 1, the general liquid crystal panel
includes a lower substrate 100 and an upper substrate 200 which are
formed of glass and are opposite each other, and a liquid crystal
layer 300 formed between the lower substrate 100 and the upper
substrate 200 and including liquid crystal molecules oriented
vertically or horizontally with respect to the two substrates 100
and 200. If the lower substrate 100 is referred to as a thin film
transistor array substrate, the upper substrate 200 is referred to
as a color filter array substrate.
[0035] A sealant (not shown) formed of a material to bond the two
substrates 100 and 200, defining a part filled with liquid
crystals, and preventing leakage of the liquid crystals may be
formed at the edges of the two substrates 100 and 200.
[0036] Further, the general liquid crystal panel may include
polarizing plates 400 polarizing light and attached to both or one
of the outer surfaces of the two substrates 100 and 200.
[0037] Further, a tab 600 may be installed on the liquid crystal
panel.
[0038] Here, the tab 600 may be an electrode electrically connected
to the thin transistor array substrate among the lower substrate
100 and the upper substrate 200. The tab 600 may be formed in a
flexible film type and include various semiconductors and
electrical elements and a circuit board including the same.
[0039] Hereinafter, a display panel manufacturing method for
manufacturing a display panel in a curved shape in accordance with
one embodiment of the present invention will be described with
reference to FIGS. 2A to 2F.
[0040] First, as exemplarily shown in FIG. 2A, if the polarizing
plate 400 is attached to one or both of the upper substrate 200 and
the lower substrate 100, all the polarizing plates 400 are
separated from the upper substrate 200 and the lower substrate
100.
[0041] The reason why the polarizing plates 400 are separated from
the upper substrate 200 and the lower substrate 100 is to perform
etching to reduce the thickness of the lower substrate 100 and the
upper substrate 200.
[0042] The separated polarizing plates 400 may be formed in a
flexible film type or a hard plate type.
[0043] As one exemplarily method of separating the polarizing plate
400 from the lower substrate 100 or the upper substrate 200, the
liquid crystal panel may be quickly cooled to a sub-zero
temperature of about -30.degree. C. or below at which an adhesive
loses viscosity.
[0044] Here, in order to prevent spotted defects on the surface of
the liquid crystal panel due to condensation of water vapor during
cooling and damages to the polarizing plates 400, separation may be
performed under a dry environmental condition.
[0045] Further, a protective film may be attached to the surfaces
of the separated polarizing plates 400 to which the adhesive is
applied and then the polarizing plates 400 may be stored for
reuse.
[0046] As other exemplary methods of separating the polarizing
plate 400 from the lower substrate 100 or the upper substrate 200,
the polarizing plate 400 may be soaked in a solvent to dissolve the
adhesive attached to the lower substrate 100 or the upper substrate
200, or a solvent may be sprayed or injected between the polarizing
plate 400 and the lower substrate 100 or the upper substrate
200.
[0047] Further, if the tab 600 is installed on the liquid crystal
panel, the tab 600 may be removed from the liquid crystal panel
before or after the polarizing plate 400 is separated from the
lower substrate 100 or the upper substrate 200.
[0048] Here, the reason why the tab 600 is removed from the liquid
crystal panel is to prevent the tab 600 from being corroded by an
etching solution or to prevent foreign substances from flowing into
the tab 600, when the lower substrate 100 and the upper substrate
200 are partially removed, as descried below.
[0049] As exemplarily shown in FIG. 2B, the outer surfaces of the
lower substrate 100 and the upper substrate 200 are removed to be
reduced to a predetermined thickness. Here, the predetermined
thickness may have a value within the range of 50 to 150 .mu.m.
[0050] The reason why the outer surfaces of the lower substrate 100
and the upper substrate 200 are removed so that the lower substrate
100 and the upper substrate 200 have a reduced thickness is to bend
the lower substrate 100 and upper substrate 200 without
breakage.
[0051] If the thickness of each of the lower substrate 100 and the
upper substrate 200 after removal of the outer surfaces of the
lower substrate 100 and the upper substrate 200 is less than 50
.mu.m or greater than 150 .mu.m, the lower substrate 100 and the
upper substrate 200 may be easily broken or may not be easily bent
during the bending process of the lower substrate 100 and the upper
substrate 200.
[0052] The outer surfaces of the lower substrate 100 and the upper
substrate 200 may be removed through a conventionally known method,
for example, a mechanical polishing method or an etching method
using an etching solution.
[0053] As exemplarily shown in FIG. 3A, when the outer surfaces of
the lower substrate 100 and the upper substrate 200 are removed,
the outer surfaces of the lower substrate 100 and the upper
substrate 200 are removed such that protrusions 110 and 210 are
formed on the lower substrate 100 and upper substrate 200.
[0054] Here, the protrusions 110 and 210 mean parts formed on the
lower substrate 100 and the upper substrate 200 allowing
transparent polymer layers 510 or transparent substrates 500, which
will be described later, to be formed on or attached to the lower
substrate 100 and the upper substrate 200 by a designated
separation distance when the transparent polymer layers 510 or the
transparent substrates 500 are formed on or attached to the lower
substrate 100 and the upper substrate 200.
[0055] The protrusions 110 and 210 may be formed at both side ends
or edges of four sides of the lower substrate 100 and the upper
substrate 200, or be formed at the middle parts of the lower
substrate 100 and the upper substrate 200.
[0056] When the outer surfaces of the lower substrate 100 and the
upper substrate 200 are removed, masking may be performed at parts
of the lower substrate 100 and the upper substrate 200 where the
protrusions 110 and 210 will be formed so that the parts of the
lower substrate 100 and the upper substrate 200 are not removed and
maintain the existing thickness.
[0057] Masking may be performed by attaching masking members to the
parts of the lower substrate 100 and the upper substrate 200 where
the protrusions 110 and 210 will be formed before the outer
surfaces of the lower substrate 100 and the upper substrate 200 are
removed, and the protrusions 110 and 210 having the existing
thickness may be formed by removing the outer surfaces of the lower
substrate 100 and the upper substrate 200 under the condition that
the masking members are attached to the parts of the lower
substrate 100 and the upper substrate 200.
[0058] Here, the masking members may be jigs surrounding parts of
the lower substrate 100 and the upper substrate 200, or masking
tapes attachable to the lower substrate 100 and the upper substrate
200.
[0059] When the protrusions 110 and 210 are formed by performing
masking using masking members, the outer surfaces of the upper
substrate 200 and the lower substrate 100 are removed through an
etching method. If the masking members are masking tapes, masking
tapes having acid resistance which are not corroded by an etching
solution may be used.
[0060] Further, if the masking members are jigs, sealing members
having acid resistance preventing an etching solution from flowing
into spaces between the lower and upper substrates 200 and 100 and
the jigs may be used. If the tab 600 is not separated from the
liquid crystal panel, jigs may be configured such that the jigs
together with the tab 600 surround the parts of the lower substrate
100 and the upper substrate 200 where the protrusions 110 and 210
will be formed.
[0061] As exemplarily shown in FIG. 3B, the protrusions 110 and 210
may be formed by attaching separation members 700 to the two
substrates 100 and 200 instead of prevention of removal of the
outer surfaces of the two substrates 100 and 200.
[0062] That is, the protrusions 110 and 210 may be formed by
attaching the separation members 700 having the thickness of the
protrusions 110 and 210 to the parts of the lower substrate 100 and
the upper substrate 200 cut to the predetermined thickness. The
separation members 700 may be attached to the lower substrate 100
and the upper substrate 200 by an adhesive.
[0063] As exemplarily shown in FIG. 2C, after the lower substrate
100 and the upper substrate 200 are reduced to the predetermined
thickness by removing the outer surfaces of the lower substrate 100
and the upper substrate 200, the liquid crystal panel is bent in a
desired curved shape.
[0064] The liquid crystal panel may be bent such that the surface
of the liquid crystal panel reproducing and displaying an image is
concave or convex, be bent by applying pressure to the liquid
crystal panel in leftward and rightward directions or in the upward
and downward direction based on the center of the liquid crystal
panel, and/or be bent in various curved shapes, such as an "S"
shape or a waveform shape.
[0065] Further, the liquid crystal panel may be bent in a partially
curved shape, for example, a "J" shape, some parts of which are
plane and the remaining parts of which are curved.
[0066] If the protrusions 110 and 210 are formed on the liquid
crystal panel, the protrusions 110 and 210 have a higher thickness
than the cut lower substrate 100 and upper substrate 200 and thus
have higher hardness than the cut lower substrate 100 and upper
substrate 200. Therefore, the liquid crystal panel may be bent
under the condition that the protrusions 110 and 210 are
gripped.
[0067] As exemplarily shown in FIG. 2D, under the condition that
the liquid crystal panel is bent, the separated polarizing plates
400 are attached again to the outer surfaces of the upper substrate
200 and the lower substrate 100.
[0068] Since the polarizing plates 400 are attached to the liquid
crystal panel in the bent state using the adhesive provided on the
polarizing plates 400, the attached polarizing plates 400 may
maintain the bent state of the liquid crystal panel.
[0069] The reason why the polarizing plates 400 are not attached to
the liquid crystal panel in the flat state but are attached to the
liquid crystal panel in the bent state is not only to relatively
reduce restoring force of the liquid crystal panel in the curved
shape to the flat state but also to prevent deformation of the
polarizing plates 400 during extended use for a long time.
[0070] As exemplarily shown in FIG. 2E, after the polarizing plates
400 are attached to the liquid crystal panel, transparent
substrates 500 which are prefabricated in the same shape as the
desired curved shape may be attached to the outer surfaces of the
lower substrate 100 and the upper substrate 200.
[0071] Here, the outer surfaces of the lower substrate 100 and the
upper substrate 200 may mean the outer surfaces of the polarizing
plates 400 attached to the lower substrate 100 and the upper
substrate 200.
[0072] The transparent substrates 500 may be substrates formed of a
transparent or semi-transparent material, such as glass or a
synthetic resin.
[0073] Further, the transparent substrates 500 mean reinforcing
plates in a curved shape which are formed of a material having high
hardness and maintaining the curved shape of the bent liquid
crystal panel so as not to be spread again into the flat shape.
[0074] The transparent substrates 500 may be attached to the entire
outer surfaces of the lower substrate 100 and the upper substrate
200, or be attached to the outer surfaces of the protrusions 110
and 210 if the protrusions 110 and 210 are formed on the lower
substrate 100 and the upper substrate 200, as exemplarily shown in
FIG. 4.
[0075] Further, an adhesive may be applied to the transparent
substrates 500 or the lower and upper substrates 100 and 200 and
then the transparent substrates 500 may be attached to the outer
surfaces of the lower and upper substrates 100 and 200 by the
adhesive, and the adhesive may be an optically clear adhesive
(OCA).
[0076] As described above, if the transparent substrates 500 bent
in advance in the desired curved shape are attached to the entire
outer surfaces of the lower and upper substrates 100 and 200 using
the adhesive, the transparent substrates 500 bent in advance
maintain the bent state of the liquid crystal panel at uniform
force and thus, deformation generated due to concentration of
bending force on some parts may be reduced and moire may be
prevented.
[0077] Further, since the transparent substrates 500 are attached
to the lower and upper substrates 100 and 200 by the adhesive
applied to the entire surfaces of the transparent substrates 500 or
the lower and upper substrates 100 and 200, inflow of air bubbles
and foreign substances between the transparent substrates 500 and
the lower and upper substrates 100 and 200 may be prevented and a
clear image of a high quality may be provided.
[0078] Further, since the adhesive forming layers between the
transparent substrates 500 and the lower and upper substrates 100
and 200 attaches the transparent substrates 500 to the lower and
upper substrates 100 and 200, the adhesive may provide uniform
adhesive force between the transparent substrates 500 bent in
advance in the desired curved shape and the liquid crystal
panel.
[0079] If the protrusions 110 and 210 are formed on the lower
substrate 100 and the upper substrate 200 and the transparent
substrates 500, i.e., reinforcing plates for maintaining the curved
shape, are attached to the outer surfaces of the protrusions 110
and 210, a transparent polymer in a liquid state may be injected
into separation spaces 800 between the transparent substrates 500
and the lower and upper substrates 100 and 200 and be hardened so
as to unify the transparent substrates 500 and the lower and upper
substrates 100 and 200 (with reference to FIG. 4).
[0080] That is, generation of moire may be prevented due to the
separation spaces 800, but foreign substances may be introduced
into the separation spaces 800 and degradation of an image quality
may be generated due to scattering of light by air layers. In order
to prevent such drawbacks, the transparent substrates 500 and the
lower and upper substrates 100 and 200 may be unified by filling
the separation spaces 800 between the transparent substrates 500
and the lower and upper substrates 100 and 200 with a transparent
polymer.
[0081] Further, the transparent polymer filling the separation
spaces 800 may perform a function of bonding the transparent
substrates 500 and the lower and upper substrates 100 and 200, thus
performing a function of firmly supporting the bent liquid crystal
panel.
[0082] Further, if the transparent polymer filling the separation
spaces 800 is hardened, the transparent polymer may perform a
function of maintaining the curved shape of the liquid crystal
panel. Therefore, together with the transparent substrates 500
serving as the reinforcing plates to maintain the curved shape, the
transparent polymer may further improve force of maintaining the
curved shape of the liquid crystal panel and thus, the thickness of
the transparent substrates 500 may be reduced.
[0083] Here, the transparent polymer may be a random transparent or
semi-transparent polymer, such as s transparent UV resin.
[0084] Further, as exemplarily shown in FIG. 2F, when the
transparent substrates 500 are attached to the lower substrate 100
and the upper substrate 200, if the tab 600 is separated from the
liquid crystal panel, the separated tab 600 is combined again with
the liquid crystal panel and thereby, manufacture of the curved
display panel is completed.
[0085] Although this embodiment describes that the tab 600 is
re-attached to the liquid crystal panel after the transparent
substrates 500 are attached to the lower substrate 100 and the
upper substrate 200, the tab 600 may be re-attached to the liquid
crystal panel before or when the transparent substrates 500 are
attached to the lower substrate 100 and the upper substrate 200, or
re-attachment of the tab 600 to the liquid crystal panel may be
performed after the transparent polymer fills the separation spaces
800 and is hardened.
[0086] Further, although this embodiment describes that the
polarizing plates 400 are attached to the lower substrate 100 and
the upper substrate 200 of the bent liquid crystal panel before the
transparent substrates 500 are attached to the liquid crystal
panel, the polarizing plates 400 may be attached to the outer
surfaces of the transparent substrates 500 after the transparent
substrates 500 are attached to the liquid crystal panel.
[0087] Therefore, the curved display panel manufactured by the
curved display panel manufacturing method in accordance with one
embodiment of the present invention may be configured such that the
lower substrate 100 and the upper substrate 200 may maintain a
desired curved shape by removing the outer surfaces of the lower
substrate 100 and the upper substrate 200 so as to have a reduced
thickness, bending the lower substrate 100 and the upper substrate
200 into the desired curved shape, and then attaching the
reinforcing plates for maintaining the curved shape, i.e., the
transparent substrates 500, to the bent lower substrate 100 and
upper substrate 200.
[0088] Hereinafter, a curved display panel manufacturing method in
accordance with another embodiment of the present invention will be
described. Some parts in this embodiment which are substantially
the same as those in the former embodiment shown in FIGS. 2A to 4
are denoted by the same reference numerals even though they are
depicted in different drawings and a detailed description of
functions and effects thereof will thus be omitted because it is
considered to be unnecessary.
[0089] The curved display panel manufacturing method in accordance
with this embodiment of the present invention is the same as the
curved display panel manufacturing method in accordance with the
former embodiment of the present invention except that transparent
polymer layers 510 are formed on a liquid crystal panel instead of
attachment of the transparent plates 500, serving as reinforcing
plates for maintaining the curved shape, to the liquid crystal
panel.
[0090] As exemplarily shown in FIGS. 5A to 5C, the transparent
polymer layers 510 bent in a desired curved shape in accordance
with this embodiment may be formed on the outer surfaces of the
polarizing plates 400 attached to the upper substrate 200 and the
lower substrate 100 of the liquid crystal panel.
[0091] Further, the transparent polymer layers 510 may be formed by
loading the bent liquid crystal panel into a mold set 900 on which
a desired curved shape of the transparent polymer layers 510 is
formed.
[0092] The thickness of the transparent polymer layers 510 to be
formed may be set before or after the liquid crystal panel is
loaded into the mold set 900 to form the transparent polymer layers
510.
[0093] For example, the thickness of the transparent polymer layers
510 to be formed may be set by inserting thin platy mold pieces
formed in the shape of the transparent polymer layers 510 and
having a random thickness into the mold set 900 or by locating the
liquid crystal panel loaded into the mold set 900 at a position
close to or distant from the positions of the transparent polymer
layers 510 to be which will be formed.
[0094] Since force of supporting the bent liquid crystal panel and
light transmittance of the liquid crystal panel vary according to
the thickness of the transparent polymer layers 510 formed on the
liquid crystal panel, setting of the thickness of the transparent
polymer layers 510 to be formed is important. The thickness of the
transparent polymer layers 510 to be formed may be frequently
changed according to a screen size of the liquid crystal panel
which will be manufactured.
[0095] Further, when the thickness of the transparent polymer
layers 510 to be formed is set, a liquid transparent polymer is
injected into the mold set 900 and then, the liquid crystal panel
is unloaded from the mold set 900 after a random time to harden the
transparent polymer has elapsed. Thereby, formation of the
transparent polymer layers 510 on the liquid crystal panel is
completed.
[0096] Here, the transparent polymer may be a random transparent or
semi-transparent polymer, such as a transparent UV resin.
[0097] When formation of the transparent polymer layers 510 on the
liquid crystal panel has been completed, a tab 600 may be attached
to the liquid crystal panel as in the former embodiment of the
present invention.
[0098] Therefore, if the transparent polymer layers 510 are formed
on the liquid crystal panel instead of the transparent substrates
500, the transparent polymer layers 510 are unified with the outer
surfaces of the lower substrate 100 and the upper substrate 200
during the hardening process of the liquid transparent polymer and
thus, as the transparent polymer layers 510 are hardened, the lower
substrate 100, the upper substrate, and the transparent polymer
layers 510 may maintain the desired curved shape.
[0099] Further, the transparent polymer layers 510 are unified with
the lower substrate 100 and the upper substrate 200 and thus,
inflow of air bubbles and foreign substances into spaces between
the transparent polymer layers 510 and the lower and upper
substrates 100 and 200 may be prevented and the liquid crystal
panel in the bent state may be firmly fixed.
[0100] Hereinafter, a curved display panel manufacturing method in
accordance with yet another embodiment of the present invention
will be described. Some parts in this embodiment which are
substantially the same as those in the former embodiment shown in
FIGS. 2A to 4 are denoted by the same reference numerals even
though they are depicted in different drawings and a detailed
description of functions and effects thereof will thus be omitted
because it is considered to be unnecessary.
[0101] The curved display panel manufacturing method in accordance
with this embodiment of the present invention is the same as the
curved display panel manufacturing method in accordance with one of
the former embodiments of the present invention except that, after
the liquid crystal panel is bent in a desired curved shape, the
separated polarizing plates 400 are not re-attached to the liquid
crystal panel and polarizing patterns are formed on the transparent
substrates 500 or the transparent polymer layers 510 in accordance
with one of the former embodiments of the present invention.
[0102] That is, the liquid crystal panel is bent in a desired
curved shape and, after or before the transparent substrates 500
are attached to or the transparent polymer layers 510 are formed on
the outer surfaces of the lower substrate 100 and the upper
substrate 200, polarizing patterns performing the function of the
polarizing plates 400 may be formed on the outer surfaces of the
transparent substrates 500 or the outer surfaces of the transparent
polymer layers 510.
[0103] These polarizing patterns are formed in the same shape as
polarizing patterns formed on the separated polarizing patterns 400
and may be formed through laser processing on the outer surfaces of
the transparent substrates 500 or the transparent polymer layers
510.
[0104] Therefore, the curved display panel manufacturing method in
accordance with this embodiment of the present invention may
prevent inflow of foreign substances due to re-attachment of the
polarizing plates 400 and manufacture a curved display panel having
a reduced thickness.
[0105] As apparent from the above description, in a curved display
panel manufacturing method in accordance with one embodiment of the
present invention, parts of outer surfaces of a lower substrate and
an upper substrate of a general liquid crystal panel are removed so
as to reduce the thickness of the lower and upper substrates, the
lower and upper substrates are bent in a curved shape, and then,
transparent polymer layers are formed on or transparent substrates
are attached to the outer surfaces of the lower and upper
substrates so as to maintain the curved shape, thus simply
manufacturing a display panel bent in a curved shape.
[0106] Although the preferred embodiments of the present invention
have been disclosed for illustrative purposes, those skilled in the
art will appreciate that various modifications, additions and
substitutions are possible, without departing from the scope and
spirit of the invention as disclosed in the accompanying
claims.
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