Display device and method of manufacturing display device

• US 10,553,794 B2
• Filed: 07/09/2018
• Issued: 02/04/2020
• Est. Priority Date: 07/13/2017
• Status: Active Grant

• Current Assignee: Japan Display Incorporated
• Original Assignee: Japan Display Incorporated
• Inventors: Nakagawa, Takuya
• Primary Examiner(s): Clark, Jasmine J
• Application Number:
  US16/030,021
• Publication Number:
  US 20190019951A1
• Time in Patent Office: 575 Days
• CPC Class Codes: B29C 41/08 Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder spray-up of reinforcing fibres B29C70/305
• CPC Class Codes: B29C 41/42 Removing articles from moulds, cores or other substrates B29C33/444 and B29C37/0017 take precedence
• CPC Class Codes: B29K 2079/08 PI, i.e. polyimides or derivatives thereof
• CPC Class Codes: B29L 2031/3475 Displays, monitors, TV-sets, computer screens
• CPC Class Codes: H10K 2102/311 Flexible OLED
• CPC Class Codes: H10K 50/844 Encapsulations
• CPC Class Codes: H10K 59/12 Active-matrix OLED [AMOLED] displays
• CPC Class Codes: H10K 59/1201 Manufacture or treatment
• CPC Class Codes: H10K 59/873 Encapsulations
• CPC Class Codes: H10K 71/00 Manufacture or treatment specially adapted for the organic devices covered by this subclass
• CPC Class Codes: H10K 71/80 using temporary substrates
• CPC Class Codes: H10K 77/111 Flexible substrates
• CPC Class Codes: Y02E 10/549 Organic PV cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A method of manufacturing a display device according to an embodiment of the present invention includes in order: forming a sacrificial layer in a predetermined position on a substrate; forming a base material containing resin on the substrate with the sacrificial layer therebetween; forming a display region including a plurality of pixels on the base material; irradiating the substrate with laser light from a side of the substrate on which the base material is not formed; and peeling the substrate from the base material. A region where the base material and the substrate are in contact with each other is present at least a part of an edge portion of the base material.

Claims

1. A method of manufacturing a display device, comprising in order:

forming a sacrificial layer in a predetermined position on a substrate;

forming a base material containing resin on the substrate with the sacrificial layer therebetween, the base material having a contact region where the base material and the substrate are in contact with each other;

forming a display region including a plurality of pixels on the base material;

irradiating the substrate with laser light from a side of the substrate on which the base material is not formed; and

peeling the substrate from the base material, wherein

a frame region outside the display region is on the base material, and

the contact region is located at at least a part of the frame region.

2. The method of manufacturing a display device according to claim 1, wherein

the frame region of the base material includes a first side,

the first side is on an edge of the base material, and

the contact region is located along the first side.

3. The method of manufacturing a display device according to claim 1, wherein

the sacrificial layer is disposed at another part,

the another part overlaps with the frame region in a plan view, and

the another part is located without overlapping with the contact region in a plan view.

4. The method of manufacturing a display device according to claim 1, wherein

the base material includes a component mounting region, and

the contact region is present in a first area and a second area,

the first area is between the display region and a first edge of the base material and includes the mounting region,

the second area is between the display region and a second edge of the base material, and

the first area and the second area are opposite side of the display region.

5. The method of manufacturing a display device according to claim 4, wherein

the display region of the base material is formed so as to be covered by the sacrificial layer.

6. The method of manufacturing a display device according to claim 1, wherein

the base material includes a component mounting region, and

the contact region is in any one of a first area and a second area,

the first area is between the display region and a first edge of the base material and includes the mounting region,

the second area is between the display region and a second edge of the base material, and

the first area and the second area are opposite side of the display region.

7. The method of manufacturing a display device according to claim 1, wherein

a first region where the base material and the substrate are in contact with each other, a second region where the sacrificial layer is present, and a third region where the base material and the substrate are in contact with each other, and

the first region, the second region and the third region are disposed in this order from an edge of the base material, and

the second region overlaps with the display region.

8. The method of manufacturing a display device according to claim 7, wherein

the sacrificial layer and the display region are adjacent to each other without overlapping with the display area in a plan view.

9. The method of manufacturing a display device according to claim 1, wherein

a first region where the sacrificial layer overlapping an edge of the base material is present, and the contact region are disposed in this order from the edge of the base material, and

the contact region includes the display region.

10. The method of manufacturing a display device according to claim 1, wherein

the sacrificial layer is disposed at least a part of an outer edge of the base material, and

the contact region is located in the display region.

11. The method of manufacturing a display device according to claim 10, wherein

the sacrificial layer is disposed at two parts along edges of the base material including the edge of the base material, and

the method further comprises removing, the sacrificial layer after irradiation with the laser light, wherein

the display region is between the two parts.

12. The method of manufacturing a display device according to claim 10, wherein

the sacrificial layer contains metal.

13. The method of manufacturing a display device according to claim 1, wherein

the sacrificial layer transmits 0% to 99% of laser light transmitted through the substrate.

14. The method of manufacturing a display device according to claim 1, wherein

the sacrificial layer contains one or more kinds selected from the group consisting of silicon nitride (SiN_y), silicon oxide (SiO_x), and a complex of SiN_y and SiO_x.

15. The method of manufacturing a display device according to claim 1, wherein

the sacrificial layer contains amorphous silicon.

16. The method of manufacturing a display device according to claim 1, wherein

the base material contains polyimide.

17. The method of manufacturing a display device according to claim 1, wherein

the substrate is a glass substrate.

18. A display device comprising:

a flexible base material; and

a plurality of pixels located on the flexible base material, wherein

a major surface of the flexible base material is a side opposite to a surface on which the plurality of pixels are formed,

the major surface has a first area and a second area,

a surface of the first area is rougher than that of the second area.

19. The display device according to claim 18, further comprising a display region including the plurality of pixels, and a frame region surrounding the display region, wherein

the first area overlaps the frame region in a plan view.

20. The display device according to claim 18, further comprising a display region including the plurality of pixels, wherein

the first area is formed in an entire region of the display region.