U.S. patent application number 17/487288 was filed with the patent office on 2022-08-18 for method of manufacturing window and window for display device.
The applicant listed for this patent is SAMSUNG DISPLAY CO., LTD.. Invention is credited to BYUNGHOON KANG, SEUNG KIM, SEUNGHO KIM, CHANGMOO LEE, HOIKWAN LEE, CHEOLMIN PARK.
Application Number | 20220258297 17/487288 |
Document ID | / |
Family ID | 1000005938870 |
Filed Date | 2022-08-18 |
United States Patent
Application |
20220258297 |
Kind Code |
A1 |
PARK; CHEOLMIN ; et
al. |
August 18, 2022 |
METHOD OF MANUFACTURING WINDOW AND WINDOW FOR DISPLAY DEVICE
Abstract
A method of manufacturing a window may include cutting a window
having a uniform thickness of about 20 .mu.m to about 100 .mu.m and
polishing a cut surface of the window with a polishing pad having
an elastic modulus less than an elastic modulus of the window while
applying slurry to the cut surface of the window.
Inventors: |
PARK; CHEOLMIN;
(HWASEONG-SI, KR) ; KIM; SEUNGHO; (ASAN-SI,
KR) ; LEE; HOIKWAN; (SUWON-SI, KR) ; KANG;
BYUNGHOON; (HWASEONG-SI, KR) ; KIM; SEUNG;
(SEONGNAM-SI, KR) ; LEE; CHANGMOO; (SUWON-SI,
KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAMSUNG DISPLAY CO., LTD. |
YONGIN-SI |
|
KR |
|
|
Family ID: |
1000005938870 |
Appl. No.: |
17/487288 |
Filed: |
September 28, 2021 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B24B 1/00 20130101; B24B
9/10 20130101; B24B 41/002 20130101; B24B 29/02 20130101; B24B 9/20
20130101; C03B 33/07 20130101; C03C 23/002 20130101; C03C 27/04
20130101 |
International
Class: |
B24B 9/10 20060101
B24B009/10; B24B 1/00 20060101 B24B001/00; B24B 9/20 20060101
B24B009/20; B24B 29/02 20060101 B24B029/02; B24B 41/00 20060101
B24B041/00; C03B 33/07 20060101 C03B033/07; C03C 23/00 20060101
C03C023/00; C03C 27/04 20060101 C03C027/04 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 16, 2021 |
KR |
10-2021-0020676 |
Claims
1. A method of manufacturing a window, the method comprising:
cutting a window, the window having a uniform thickness within a
range of about 20 .mu.m to about 100 .mu.m; applying a slurry to a
cut surface of the window; and polishing the cut surface of the
window with a polishing pad while the slurry is applied to the cut
surface of the window, wherein the polishing pad has an elastic
modulus that is less than an elastic modulus of the window.
2. The method of claim 1, wherein the window includes glass and/or
plastic.
3. The method of claim 1, wherein a hardness of the polishing pad
is less than a hardness of the window.
4. The method of claim 1, wherein the polishing pad includes a
fabric, wool, and/or a polymer.
5. The method of claim 1, wherein the slurry includes cerium(IV)
oxide (CeO.sub.2).
6. The method of claim 1, wherein polishing the cut surface of the
window includes polishing the window to reduce its length within a
range of from about 10% to about 200% of a thickness of the
window.
7. The method of claim 1, further comprising: before the cutting of
the window, or after the cutting of the window and before the
polishing of the cut surface of the window, forming a first
adhesive layer and a second adhesive layer respectively on a first
surface of the window and a second surface of the window opposite
to the first surface.
8. The method of claim 7, wherein an elastic modulus of each of the
first adhesive layer and the second adhesive layer is less than the
elastic modulus of the window.
9. The method of claim 7, wherein a hardness of each of the first
adhesive layer and the second adhesive layer is less than a
hardness of the window.
10. The method of claim 7, wherein each of the first adhesive layer
and the second adhesive layer includes a resin, an optically clear
adhesive (OCA), a rosin, and/or a wax.
11. The method of claim 7, further comprising: after the polishing
of the cut surface of the window, curing the window, the first
adhesive layer, and the second adhesive layer, and separating each
of the first adhesive layer and the second adhesive layer from the
window.
12. The method of claim 1, further comprising: after the cutting of
the window and before the polishing of the cut surface of the
window, disposing the window between a first support and a second
support.
13. The method of claim 12, wherein an area of each of the first
support and the second support is less than an area of the
window.
14. A window for a display device, the window comprising: a flat
portion having a uniform thickness within a range of about 20 .mu.m
to about 100 .mu.m; and a chamfer portion disposed on at least a
portion of an edge of the flat portion, the chamfer portion having
an average thickness that is less than a thickness of the flat
portion, and having an outer surface of a curved shape protruding
from the flat portion.
15. The window of claim 14, wherein a roughness of the outer
surface of the chamfer portion is about 0.5 nm to about 10 nm.
16. The window of claim 14, wherein a distance from an edge of the
chamfer portion to the edge of the flat portion is in a range of
about 10% to about 200% of a thickness of the flat portion.
17. The window of claim 14, wherein the chamfer portion includes a
first curved portion adjacent to a first surface of the flat
portion and a second curved portion adjacent to a second surface of
the flat portion that is opposite to the first surface of the flat
portion, and wherein a radius of curvature of each of the first
curved portion and the second curved portion is in a range of from
about 10% to about 50% of a thickness of the flat portion.
18. The window of claim 14, wherein the chamfer portion has a
single uniform radius of curvature, and wherein the single uniform
radius of curvature is in a range of from about 50% to about 100%
of a thickness of the flat portion.
19. The window of claim 14, wherein the chamfer portion has
multiple different radiuses of curvature along the outer surface of
the chamfer portion, and wherein each of the multiple radiuses of
curvature along the outer surface of the chamfer portion is in a
range of from about 20% to about 200% of a thickness of the flat
portion.
20. The window of claim 19, wherein the outer surface of the
chamfer portion adjacent to a surface of the flat portion has an
included angle of about 10 degrees to about 30 degrees with respect
to a plane of the flat portion.
21. A method of manufacturing a window of a display device, the
method comprising: alternately stacking a plurality of windows and
a plurality of adhesive layers into a single stack; cutting the
single stack; polishing a cut surface of the single stack using a
polishing pad while a slurry is applied to the cut surface of the
single stack; curing the single stack; and separating each of the
plurality of windows from the single stack after the single stack
has been cured, wherein the polishing pad has an elastic modulus
that is less than an elastic modulus of the window.
22. The method of claim 21, wherein the curing includes exposing
the single stack to UV light and emerging the single stack into a
bath of hot water.
23. The method of claim 21, wherein the polishing of the cut
surface of the single stack includes polishing each of the
plurality of adhesive layers shorter than each of the plurality of
windows such that edges of each of the plurality of windows extend
past corresponding edges of each of the plurality of adhesive
layers.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority under 35 USC .sctn. 119 to
Korean Patent Application No. 10-2021-0020676 filed on Feb. 16,
2021 in the Korean Intellectual Property Office (KIPO), the entire
disclosure of which is herein incorporated by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to a method of manufacturing
a window. More particularly, the present disclosure relates to a
window applied to various display devices and a method of
manufacturing the window.
DISCUSSION OF THE RELATED ART
[0003] A display device is an electronic device that provides
visual information to a user. Recently, display devices have been
developed that are bendable, foldable, or rollable. These display
panels are, in some cases, able to be bent, folded, or rolled
during the manufacturing process and are then locked into a desired
shape. On other cases, these display panels may be repeatedly bent,
folded, or rolled during use.
[0004] The display device may include a window for protecting a
display panel that generates an image. In these cases, both the
display panel and the window might be flexible.
[0005] The window may be cut to correspond to the size of the
display device during a manufacturing process. A cut surface of the
window may be chemically polished with an etchant in order to
remove defects or the like of the cut surface of the window.
However, when the cut surface of the window is chemically polished,
grains are formed on an edge of the window by a chemical reaction
between the etchant and the window, and as an outer surface of the
edge of the window is angled, an impact strength of the window may
decrease.
SUMMARY
[0006] A method of manufacturing a window of a display device, the
method includes alternately stacking a plurality of windows and a
plurality of adhesive layers into a single stack; cutting the
single stack; polishing a cut surface of the single stack using a
polishing pad while a slurry is applied to the cut surface of the
single stack; curing the single stack; and separating each of the
plurality of windows from the single stack after the single stack
has been cured. The polishing pad has an elastic modulus that is
less than an elastic modulus of the window.
[0007] The curing may include exposing the single stack to UV light
and emerging the single stack into a bath of hot water.
[0008] The polishing of the cut surface of the single stack may
include polishing each of the plurality of adhesive layers shorter
than each of the plurality of windows such that edges of each of
the plurality of windows extend past corresponding edges of each of
the plurality of adhesive layers.
[0009] A method of manufacturing a window includes cutting a window
having a uniform thickness of about 20 .mu.m to about 100 .mu.m and
polishing a cut surface of the window with a polishing pad having
an elastic modulus that is less than an elastic modulus of the
window, while applying a slurry to the cut surface of the
window.
[0010] The window may include glass and/or plastic.
[0011] A hardness of the polishing pad may be less than a hardness
of the window.
[0012] The polishing pad may include a fabric, wool, and/or a
polymer.
[0013] The slurry may include cerium(IV) oxide (CeO.sub.2).
[0014] Polishing the cut surface of the window may include
polishing the window to remove a length measured from an edge of
the window that is equal to about 10% to about 200% of the
thickness of the window.
[0015] The method may further include, before cutting the window,
or after cutting the window and before polishing the cut surface of
the window, forming a first adhesive layer and a second adhesive
layer on a first surface of the window and a second surface of the
window that is opposite to the first surface of the window,
respectively.
[0016] An elastic modulus of each of the first adhesive layer and
the second adhesive layer may be less than the elastic modulus of
the window.
[0017] A hardness of each of the first adhesive layer and the
second adhesive layer may be less than a hardness of the
window.
[0018] Each of the first adhesive layer and the second adhesive
layer may include a resin, an optically clear adhesive (OCA), a
rosin, and/or a wax.
[0019] The method may further include, after polishing the cut
surface of the window, curing each of the window, the first
adhesive layer, and the second adhesive layer and separating the
first adhesive layer and the second adhesive layer from the
window.
[0020] The method may further include, after cutting the window and
before polishing the cut surface of the window, disposing the
window between a first support and a second support.
[0021] An area of each of the first support and the second support
may be less than an area of the window.
[0022] A window for a display device includes a flat portion having
a uniform thickness of about 20 .mu.m to about 100 .mu.m and a
chamfer portion disposed on at least a portion of an edge of the
flat portion, having a thickness less than the thickness of the
flat portion, and having an outer surface of a curved shape
protruding from the flat portion.
[0023] A roughness of the outer surface of the chamfer portion may
be about 0.5 nm to about 10 nm.
[0024] A distance from an edge of the chamfer portion to the edge
of the flat portion may be in a range of about 10% to about 200% of
the thickness of the flat portion.
[0025] The chamfer portion may include a first curved portion
adjacent to a first surface of the flat portion and a second curved
portion adjacent to a second surface of the flat portion opposite
to the first surface. A radius of curvature of each of the first
curved portion and the second curved portion may be in a range of
about 10% to about 50% of the thickness of the flat portion.
[0026] The chamfer portion may have a uniform radius of curvature.
The radius of curvature may be in a range of about 50% to about
100% of the thickness of the flat portion.
[0027] The chamfer portion may have different radiuses of curvature
along the outer surface of the chamfer portion. The radius of
curvature on an edge of the chamfer portion may be in a range of
about 20% to about 200% of the thickness of the flat portion.
[0028] The outer surface of the chamfer portion adjacent to a
surface of the flat portion may have an angle of about 10 degrees
to about 30 degrees with respect to a plane extending from the
surface of the flat portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] A more complete appreciation of the present disclosure and
many of the attendant aspects thereof will be readily obtained as
the same becomes better understood by reference to the following
detailed description when considered in connection with the
accompanying drawings, wherein:
[0030] FIG. 1 is a flowchart illustrating a method of manufacturing
a window according to an embodiment of the present disclosure;
[0031] FIGS. 2, 3, 4, 5, 6, 7, 8, and 9 are diagrams illustrating a
method of manufacturing a window according to an embodiment of the
present disclosure;
[0032] FIG. 10 is a flowchart illustrating a method of
manufacturing a window according to an embodiment of the present
disclosure;
[0033] FIGS. 11 and 12 are diagrams illustrating a method of
manufacturing a window according to an embodiment of the present
disclosure;
[0034] FIG. 13 is a flowchart illustrating a method of
manufacturing a window according to an embodiment of the present
disclosure;
[0035] FIG. 14 is a diagram illustrating a method of manufacturing
a window according to an embodiment of the present disclosure;
[0036] FIG. 15 is a plan view illustrating a window for a display
device according to embodiments of the present disclosure;
[0037] FIG. 16 is a perspective view illustrating a window for a
display device according to an embodiment of the present
disclosure;
[0038] FIG. 17 is a perspective view illustrating a window for a
display device according to an embodiment of the present
disclosure;
[0039] FIG. 18 is a perspective view illustrating a window for a
display device according to an embodiment of the present
disclosure; and
[0040] FIG. 19 is a perspective view illustrating a window for a
display device according to an embodiment of the present
disclosure.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0041] Hereinafter, methods of manufacturing windows and windows
for display devices in accordance with embodiments of the present
disclosure will be explained in detail with reference to the
accompanying drawings.
[0042] Hereinafter, a method of manufacturing a window according to
an embodiment of the present disclosure will be described with
reference to FIGS. 1 to 9.
[0043] FIG. 1 is a flowchart illustrating a method of manufacturing
a window according to an embodiment of the present disclosure.
[0044] Referring to FIG. 1, a method of manufacturing a window
according to an embodiment of the present disclosure may include
alternately stacking windows and adhesive layers (S110), cutting
the stacked windows and the adhesive layers (S120), polishing cut
surfaces of the stacked windows and the adhesive layers (S130),
UV-curing the stacked windows and the adhesive layers (S140),
heat-curing the stacked windows and the adhesive layers (S150), and
separating the individual windows and the adhesive layers from the
stack (S160).
[0045] FIGS. 2, 3, 4, 5, 6, 7, 8, and 9 are diagrams illustrating a
method of manufacturing a window according to an embodiment of the
present disclosure.
[0046] Referring to FIGS. 1 and 2, the windows 100 and the adhesive
layers 200 may be stacked (S110). The windows 100 and the adhesive
layers 200 may be alternately stacked, one-by-one, along a first
direction DR1. Each window 100 may be a window for a display
device. In an embodiment of the present disclosure, each window 100
may be a window for a flexible display device. Each window 100 may
protect components of a display device, and an image generated by
the display device may be displayed through the window 100 as the
window may be transparent to visible light. As the windows 100 and
the adhesive layers 200 are alternately stacked, a plurality of
windows 100 may be cut together in a subsequent process, and a
cutting time and a cutting cost of the windows 100 may be reduced
as compared to a process in which each window 100 is individually
cut.
[0047] Each window 100 may include a flexible material. For
example, each window 100 may include thin glass and/or plastic. The
thin glass may be of a thickness that allows for flexibility
without cracking or otherwise breaking.
[0048] Each window 100 may have a uniform thickness TH. The
thickness TH of each window 100 may be defined as a length of the
window 100 in the first direction DR1. The thickness TH of each
window 100 may be about 20 .mu.m to about 100 .mu.m. When the
thickness TH of the window 100 is less than about 20 .mu.m,
handling of the window 100 may be difficult, and the window 100
might not sufficiently protect the components of the display
device. When the thickness TH of the window 100 is greater than
about 100 .mu.m, the flexible characteristic of the window 100 may
decrease, and a flexural strength of the window 100 may
decrease.
[0049] The adhesive layers 200 may serve to fix the stacked windows
100 to one another. Accordingly, the adhesive layers 200 may each
include an adhesive material. For example, the adhesive layers 200
may each include a resin, an optically clear adhesive (OCA), a
rosin, and/or a wax.
[0050] An elastic modulus of each adhesive layer 200 may be less
than an elastic modulus of each window 100. Further, a hardness of
each adhesive layer 200 may be less than a hardness of each window
100.
[0051] Referring to FIGS. 1 and 3, the stacked windows 100 and
adhesive layers 200 may be cut (S120). The stacked windows 100 and
adhesive layers 200 may be cut together by a blade or laser beam
600. For example, the stacked windows 100 and adhesive layers 200
may be cut using computer numerical control (CNC). As the stacked
windows 100 and adhesive layers 200 are cut together, areas of the
cut adhesive layers 200 may be substantially equal to areas of the
cut windows 100. This is to say, an area of each adhesive layer 200
is substantially equal to an area of each window 100.
[0052] Each of the cut windows 100 may have a size corresponding to
a size of one display device. For example, the window 100 may be
cut such that each of the cut windows 100 is included in one
display device.
[0053] Referring to FIGS. 1 and 4, the cut surfaces of the windows
100 and the adhesive layers 200 may be polished (S130). The cut
surfaces of the windows 100 and the adhesive layers 200 may
correspond to edges of the cut windows 100 and adhesive layers
200.
[0054] The cut surfaces of the windows 100 and the adhesive layers
200 may be polished with a polishing pad 300 while applying slurry
400 to the cut surfaces of the windows 100 and the adhesive layers
200. The polishing pad 300 may rotate clockwise or counterclockwise
along a rotation axis extending in the first direction DR1. The
slurry 400 may contact the cut surfaces of the windows 100 due to
the rotation of the polishing pad 300, and may directly polish the
cut surfaces of the windows 100.
[0055] The polishing pad 300 may include a fabric, wool, and/or a
polymer. The slurry 400 may include cerium(IV) oxide (CeO.sub.2),
which may be called "ceria".
[0056] An elastic modulus of the polishing pad 300 may be less than
an elastic modulus of each window 100. Further, a hardness of the
polishing pad 300 may be less than a hardness of each window
100.
[0057] FIG. 5 is a diagram illustrating one window 100 and two
adhesive layers 210 and 220, before polishing, and FIG. 6 is a
diagram illustrating the window 100 and the adhesive layers 210 and
220 after polishing.
[0058] Referring to FIGS. 5 and 6, a first adhesive layer 210 may
be formed on a first surface 101 of the cut window 100, and a
second adhesive layer 220 may be formed on a second surface 102 of
the cut window 100 opposite to the first surface 101. For example,
the first surface 101 and the second surface 102 of the window 100
may be a lower surface and an upper surface of the window 100,
respectively.
[0059] The cut surfaces of the window 100 and the adhesive layers
210 and 220 before polishing may be parallel to each other. For
example, the edges of the window 100 and the adhesive layers 210
and 220 before polishing might not protrude or recess in a second
direction DR2 crossing the first direction DR1.
[0060] Defects formed during the cutting process of the window 100
may remain on the cut surface of the window 100 before polishing.
These defects, if left to remain on the cut surface of the window
100, might reduce the bending strength of the window 100.
[0061] A corner having a right-angled shape in a cross-sectional
view may be formed at each of opposite ends of the cut surface of
the window 100 before polishing. For example, the cut window 100
may have a rectangular prism shape in which all corners are right
angles. However, the corners of the window 100 that were cut will
have right angles even if one or more of the other corners of the
window 100 are not at right angles. For example, the corner may be
formed at each of a first end of the cut surface of the window 100
before polishing where the cut surface contacts the first surface
101 and a second end of the cut surface of the window 100 before
polishing where the cut surface contacts the second surface
102.
[0062] Edges of the window 100 and the adhesive layers 210 and 220
after polishing might not be parallel to each other. The edge of
the window 100 after polishing may protrude in the second direction
DR2 farther than the edges of the adhesive layers 210 and 220 after
polishing.
[0063] As the cut surface of the window 100 is polished, the
defects that remain on the cut surface of the window 100 may be
removed. Accordingly, the flexural strength of the window 100 may
increase by polishing, and the flexural strength of the window 100
after polishing may be relatively large.
[0064] Since the elastic modulus and the hardness of the adhesive
layers 210 and 220 are less than the elastic modulus and the
hardness of the window 100, respectively, the amount of polishing
of the adhesive layers 210 and 220 by the polishing pad 300 and the
slurry 400 may be greater than the amount of polishing of the
window 100 by the polishing pad 300 and the slurry 400.
Accordingly, in addition to the cut surface of the window 100, the
first surface 101 of the window 100 in contact with the first
adhesive layer 210 and the second surface 102 of the window 100 in
contact with the second adhesive layer 220 may be polished.
Accordingly, the window 100 after polishing may include a flat
portion 100 that is not polished and a chamfer portion 120 that is
polished. The flat portion 110 may overlap the polished adhesive
layers 210 and 220, and may have a uniform thickness TH. The
chamfer portion 120 may be disposed on an edge of the flat portion
110, and may protrude in the second direction DR2 farther than the
polished adhesive layers 210 and 220. The chamfer portion 120 may
correspond to a bezel of the display device including the window
100.
[0065] The window 100 may be polished so as to reduce the length
thereof in the DR2 direction by about 10% to about 200% of the
thickness TH of the window 100 in the DR1 direction. A distance in
the second direction DR2 from the edge of the chamfer portion 120
to the edge of the flat portion 110 may be defined as a polishing
distance PD, and the polishing distance PD may be about 10% to
about 200% of the thickness TH of the window 100. When the
polishing distance PD is less than about 10% of the thickness TH of
the window 100, the polishing pad 300 might not sufficiently polish
the cut surface of the window 100. When the polishing distance PD
is greater than about 200% of the thickness TH of the window 100, a
width of the chamfer portion 120 in the second direction DR2 may
increase to a predetermined width or more, accordingly, the bezel
of the display device including the window 100 may increase by more
than a predetermined width.
[0066] The polishing distance PD may be controlled based on a
polishing pressure and a polishing time. The type of slurry used
may also affect polishing distance PD. The polishing distance PD
may be proportional to the polishing pressure and the polishing
time. For example, the polishing distance PD may decrease as the
polishing pressure and the polishing time decrease, and the
polishing distance PD may increase as the polishing pressure and
the polishing time increase.
[0067] Referring to FIGS. 1 and 7, the windows 100 and the adhesive
layers 200 which are polished may be UV-cured (S140). A UV curing
machine 700 disposed in the first direction DR1 from the windows
100 and the adhesive layers 200 which are polished may irradiate
the windows 100 and the adhesive layers 200 with ultraviolet (UV)
light, so that the windows 100 and the adhesive layers 200 may be
UV-cured. The UV curing machine 700 may be or may include, for
example, on or more UV lamp, bulb, light-emitting diode (LED),
etc.
[0068] Referring to FIGS. 1 and 8, the windows 100 and the adhesive
layers 200 which are UV-cured may be heat-cured (S150). The windows
100 and the adhesive layers 200 which are UV-cured may be immersed
in a water tank 800 containing hot water HW to heat-cure the
windows 100 and the adhesive layers 200. The hot water HW may be of
a temperature within a range from 22.degree. C. to 100.degree.
C.
[0069] Referring to FIGS. 1 and 9, the windows 100 and the adhesive
layers 200 which are heat-cured may be separated (S160). The
adhesive strengths of the adhesive layers 200 may be reduced
through UV-curing and heat-curing, and accordingly, the windows 100
and the adhesive layers 200 may be easily separated from one
another.
[0070] Hereinafter, a method of manufacturing a window according to
an embodiment of the present disclosure will be described with
reference to FIGS. 10 to 12.
[0071] FIG. 10 is a flowchart illustrating a method of
manufacturing a window according to an embodiment of the present
disclosure.
[0072] Referring to FIG. 10, a method of manufacturing a window
according to an embodiment of the present disclosure may include
cutting windows (S210), stacking the windows and adhesive layers
(S220), polishing cut surfaces of the windows and the adhesive
layers (S230), UV-curing the windows and the adhesive layers
(S240), heat-curing the windows and the adhesive layers (S250), and
separating the windows and the adhesive layers (S260). In a method
for manufacturing the window according to an embodiment of the
present disclosure, polishing the cut surfaces of the windows and
the adhesive layers (S230), UV-curing the windows and the adhesive
layers (S240), heat-curing the windows and the adhesive layers
(S250), and separating the windows and the adhesive layers (S260)
are substantially the same as or similar to polishing the cut
surfaces of the windows and the adhesive layers (S130), UV-curing
the windows and the adhesive layers (S140), heat-curing the windows
and the adhesive layers (S150), and separating the windows and the
adhesive layers (S160) of the method for manufacturing the window
discussed above, respectively. Accordingly, to the extent that
descriptions of steps S230, S240, S250, and S260 are not provided
herein, it may be assumed that these steps are at least similar to
steps S130, S140, S150, and S160, respectively.
[0073] FIGS. 11 and 12 are diagrams illustrating a method of
manufacturing the window according to an embodiment of the present
disclosure.
[0074] Referring to FIGS. 10 and 11, the windows 100 may be cut
(S210). Each of the windows 100 may be individually cut as opposed
to being cut in a stack, as explained above. The window 100 may be
cut by irradiating the window 100 with a laser beam LB from a laser
cutter 900 disposed in the first direction DR1 from the window 100.
Each of the cut windows 100 may have a size corresponding to the
size of one display device.
[0075] Referring to FIGS. 10 and 12, the cut windows 100 and the
adhesive layers 200 may be stacked (S220). The windows 100 and the
adhesive layers 200 may be alternately stacked along the first
direction DR1. Areas of the adhesive layers 200 may be
substantially equal to areas of the cut windows 100. Thus, here,
the windows 100 and adhesive layers 200 are stacked after cutting
as opposed to prior to cutting, which was discussed above.
[0076] FIG. 13 is a flowchart illustrating a method of
manufacturing a window according to an embodiment of the present
disclosure.
[0077] Referring to FIG. 13, the method of manufacturing the window
according to an embodiment of the present disclosure may include
cutting a window (S310), disposing the window between support
members (S320), and polishing a cut surface of the window (S330).
In the method for manufacturing the window according to an
embodiment of the present disclosure, cutting the window (S310) and
polishing the cut surface of the window (S330) are substantially
the same as or similar to cutting the windows (S210) and polishing
the cut surfaces of the windows and the adhesive layers (S230) of
the method for manufacturing the window described above,
respectively. Accordingly, to the extent that descriptions on the
steps S310 and S330 are not provided, it may be assumed that these
steps are at least similar to the steps of cutting S210 and
polishing S230 discussed above, respectively.
[0078] FIG. 14 is a diagram illustrating a method of manufacturing
a window according to an embodiment of the present disclosure.
[0079] Referring to FIGS. 13 and 14, the cut window 100 may be
disposed between the supporting members 510 and 520 (S310). A first
support member 510 may be disposed on a first surface of the cut
window 100, and a second support member 520 may be disposed on a
second surface of the cut window 100 opposite to the first surface.
The support members 510 and 520 may support the window 100 in the
process of polishing the cut window 100. The support members 510
and 520 may each be a support block (referred to herein simply as
"a support") and these supports 510 and 520 may contain the window
100 and keep it in place by the force of the supports 510 and 520
pushing toward each other like a vice and/or by friction.
[0080] An area of each of the first support member 510 and the
second support member 520 may be less than an area of the window
100 causing the window 100 to overhang the first support member 510
and the second support member 520. Accordingly, in the process of
polishing the cut surface of the window 100, the first surface of
the window 100 which contacts the first support member 510 and the
second surface of the window 100 which contacts the second support
member 520 as well as the cut surface of the window 100 may be
polished. Accordingly, an edge of the polished window 100 may have
a curved outer surface.
[0081] In a method of manufacturing a window according to an
embodiment of the present disclosure, the process of stacking the
window 100 and an adhesive layer, curing the window 100 and the
adhesive layer, and separating the window 100 and the adhesive
layer may be omitted because the cut surface of one window 100 is
polished without the use of an adhesive layer.
[0082] In the prior art, a window may be polished in a chemical
manner using an etchant. In this case, grains may be formed on a
cut surface of the window by a chemical reaction between the
etchant and the cut surface of the window, and accordingly, the
roughness of the cut surface of the window may increase. When the
roughness of the cut surface of the window increases, the impact
strength of the cut surface of the window may decrease. In
addition, when the window is polished in the chemical manner, an
outer surface of an edge of the window may be angled, and
accordingly, the impact strength of the cut surface of the window
may decrease.
[0083] Further, in the prior art, chemical substances (e.g.,
hydrofluoric acid, sulfuric acid, nitric acid, phosphoric acid,
etc.) included in the etchant used in chemical polishing may cause
environmental pollution. Moreover, an etchant rinse process may be
additionally required to remove the chemical substances.
[0084] In the embodiments of the present invention, the window 100
may be polished in a mechanical manner using the polishing pad 300
and the slurry 400. In this case, grains might not be formed on the
cut surface of the window 100, and accordingly, the roughness of
the cut surface of the window 100 may decrease. Accordingly, the
impact strength of the cut surface of the window 100 may increase.
Further, when the window 100 is polished in the mechanical manner,
the outer surface of the edge of the window 100 may be formed to be
rounded, and accordingly, the impact strength of the cut surface of
the window 100 may increase.
[0085] Further, in the embodiments of the present invention, the
slurry 400 used in mechanical polishing might not cause
environmental pollution because the slurry 400 may simply be an
abrasive compound that does not contain a chemical substance.
Moreover, since no chemical substances are used in the polishing
process of the window 100, the etchant rinse process of the prior
art may be omitted.
[0086] Hereinafter, a window for a display device according to
embodiments of the present disclosure will be described with
reference to FIGS. 15 to 19.
[0087] FIG. 15 is a plan view illustrating a window 100 for a
display device according to embodiments of the present disclosure.
FIG. 16 is a perspective view illustrating a window 100 for a
display device according to an embodiment of the present
disclosure. FIG. 16 may illustrate an example of an area A in FIG.
15.
[0088] Referring to FIGS. 15 and 16, a window 100 may include a
flat portion 110 and a chamfer portion 120. The flat portion 110
may have a rectangular shape with rounded corners in a plan view.
However, the planar shape of the flat portion 110 is not
necessarily limited thereto, and the flat portion 110 may have
various planar shapes such as a polygonal planar shape, a circular
planar shape, an elliptical planar shape, or the like.
[0089] The flat portion 110 may have a uniform thickness TH. The
thickness TH of the flat portion 110 may be about 20 .mu.m to about
100 .mu.m. When the thickness TH of the flat portion 110 is less
than about 20 .mu.m, handling of the window 100 may be difficult,
and the window 100 might not sufficiently protect the components of
the display device. When the thickness TH of the flat portion 110
is greater than about 100 .mu.m, the flexible characteristic of the
window 100 may decrease.
[0090] The chamfer portion 120 may be disposed on at least a
portion of an edge of the flat portion 110. For example, the
chamfer portion 120 may surround at least a portion of the flat
portion 110. In an embodiment of the present disclosure, as
illustrated in FIG. 15, the chamfer portion 120 may be disposed on
an entire edge of the flat portion 110 to fully surround the flat
portion 110.
[0091] The bezel of the display device may overlap at least the
chamfer portion 120. In an embodiment, the bezel of the display
device may overlap an entirety of the chamfer portion 120 and a
part of the flat portion 110 adjacent to the chamfer portion 120,
and a black matrix or other light-blocking pattern may be formed on
the bezel.
[0092] The chamfer portion 120 may have a thickness less than the
thickness TH of the flat portion 110. The thickness of the chamfer
portion 120 may decrease along the second direction DR2 from the
edge of the flat portion 110 toward the edge of the chamfer portion
120.
[0093] The chamfer portion 120 may have a curved outer surface
protruding from the flat portion 110. The outer surface of the
chamfer portion 120 may have a relatively small roughness. In an
embodiment, the roughness of the outer surface of the chamfer
portion 120 may be about 0.5 nm to about 10 nm. As described above,
the window 100 may be polished in a mechanical manner using the
polishing pad 300 and the slurry 400, and accordingly, the outer
surface of the chamfer portion 120 may have a relatively small
roughness (i.e., it may be relatively smooth). Accordingly, the
window 100 may have a relatively high impact strength.
[0094] A distance from the edge of the chamfer portion 120 to the
edge of the flat portion 110 may be about 10% to about 200% of the
thickness TH of the flat portion 110. The distance from the edge of
the chamfer portion 120 to the edge of the flat portion 110 in the
second direction DR2 may be defined as a polishing distance PD.
When the polishing distance PD is less than about 10% of the
thickness TH of the flat portion 110, defects generated during the
cutting process of the window 100 may remain on the outer surface
of the chamfer portion 120. When the polishing distance PD is
greater than about 200% of the thickness TH of the flat portion
110, the width of the chamfer portion 120 in the second direction
DR2 may increase to a predetermined width or more, and accordingly,
the bezel of the display device including the window 100 may
increase by more than a predetermined width.
[0095] The chamfer portion 120 may include a first curved portion
121 adjacent to a first surface 111 of the flat portion 110 and a
second curved portion 122 adjacent to a second surface 112 of the
flat portion 110 opposite to the first surface 111. Each of a
radius of curvature RCA of the first curved portion 121 and a
radius of curvature RC2 of the second curved portion 122 may be
about 10% to about 50% of the thickness TH of the flat portion
110.
[0096] FIG. 17 is a perspective view illustrating a window 100 for
a display device according to an embodiment of the present
disclosure. FIG. 17 may illustrate an example of the area A in FIG.
15.
[0097] Referring to FIG. 17, the chamfer portion 120 may have a
uniform radius of curvature RC3. The radius of curvature RC3 of the
chamfer portion 120 may be about 50% to about 100% of the thickness
TH of the flat portion 110.
[0098] The polishing pressure and the polishing time in the process
of manufacturing the window 100 discussed here may be greater than
the polishing pressure and the polishing time in the process of
manufacturing the window 100 discussed above. For example, the
polishing distance PD of the window 100 discussed here may be
greater than the polishing distance PD of the window 100 discussed
above. For example, the polishing distance PD of the window 100
discussed above may be about 20% to about 30% of the thickness TH
of the flat portion 110, and the polishing distance PD of the
window 100 discussed here may be about 50% of the thickness TH of
the flat portion 110.
[0099] FIG. 18 is a perspective view illustrating a window 100 for
a display device according to an embodiment of the present
disclosure. FIG. 18 may illustrate an example of the area A in FIG.
15. FIG. 19 is a perspective view illustrating a window 100 for a
display device according to an embodiment of the present
disclosure. FIG. 19 may illustrate an example of the area A in FIG.
15.
[0100] Referring to FIGS. 18 and 19, the chamfer portion 120 may
have different radiuses of curvature from each other along the
outer surface of the chamfer portion 120. The radiuses of curvature
RC4 and RC5 of the chamfer portion 120 at the edge of the chamfer
portion 120 may be about 20% to about 200% of the thickness TH of
the flat portion 110.
[0101] The outer surface of the chamfer portion 120 adjacent to a
surface of the flat portion 110 may have an included angle IA of
about 10 degrees to about 30 degrees with respect to an imaginary
surface extending from the surface of the flat portion 110. For
example, the included angle IA between the outer surface of the
chamfer portion 120 adjacent to the second surface 112 of the flat
portion 110 and an imaginary surface extending from the second
surface 112 of the flat portion 110 may be about 10 degrees to
about 30 degrees.
[0102] The polishing pressure and the polishing time in the process
of manufacturing the window 100 according to an embodiment of the
present disclosure may be greater than the polishing pressure and
the polishing time in the process of manufacturing the window 100
according to the approach described above, respectively. For
example, the polishing distance PD of the window 100 discussed here
may be greater than the polishing distance PD of the window 100
discussed above. For example, the polishing distance PD of the
window 100 discussed here may be about 100% of the thickness TH of
the flat portion 110.
[0103] The polishing pressure and polishing time in the process of
manufacturing the window 100 according to an embodiment of the
present disclosure may be greater than the polishing pressure and
the polishing time in the process of manufacturing the window 100
discussed above, respectively. For example, the polishing distance
PD of the window 100 discussed here may be greater than the
polishing distance PD of the window 100 discussed above. For
example, the polishing distance PD of the window 100 discussed here
may be about 150% of the thickness TH of the flat portion 110.
[0104] In the prior art, the window may be polished in a chemical
manner. In this case, the roughness of the cut surface of the
window may increase, and the outer surface of the edge of the
window may be angled. Accordingly, the impact strength of the cut
surface of the window may be reduced.
[0105] In an embodiments of the present invention, the window 100
may be polished in a mechanical manner. In this case, the roughness
of the cut surface of the window 100 may be reduced, and the outer
surface of the edge of the window 100 may be rounded. Accordingly,
the impact strength of the cut surface of the window 100 may
increase.
[0106] The window according to an embodiments of the present
disclosure may be applied to a display device included in a
computer monitor, a notebook computer, a mobile phone, a smart
phone, a smart pad, a tablet computer, a personal media player
(PMP), a personal digital assistant (PDA), an MP3 player, or the
like.
[0107] Although the methods of manufacturing the windows and the
windows for the display devices according to the embodiments have
been described with reference to the drawings, the illustrated
embodiments are examples, and may be modified and changed by a
person having ordinary knowledge in the relevant technical field
without departing from the technical spirit of the present
disclosure.
* * * * *