JP2017227708A - Curved display and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a curved display that reduces a residual stress generated between a curved protective plate and a display panel.SOLUTION: A curved display comprises a display panel 20, and a curved plate-like protective housing 10 that includes a curved sheet-like internal space 30 and surrounds the internal space. The protective housing 10 includes an opening 31 in part of the outer periphery for communicating the internal space 30 and the outside of the protective housing 10, and the display panel 20 is arranged in the internal space 30.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a curved display device and a manufacturing method thereof.

  In recent years, demand for a curved display device having a curved screen instead of a flat surface as in the past has been increasing in in-vehicle display devices and the like. In-vehicle display devices are required to have quality and reliability in an in-vehicle environment. For example, from the viewpoint of robustness and safety, an in-vehicle display device generally has a structure in which the front surface is covered with a protective plate. Patent Document 1 discloses a curved display device with a protective plate obtained by bonding a curved protective plate and a display panel with an adhesive. Note that OCA (Optical Clear Adhesive) is generally used as an adhesive for bonding the protective plate and the display panel.

JP 2010-156784 A

  FIG. 13A is a cross-sectional view showing a conventional curved display device. In the manufacturing method of the curved display device shown in FIG. 13A, bonding is performed by the OCA 83 while the flat display panel 82 is pressed against the convex surface of the curved protective plate 81 with a strong pressure and curved. As a result, the curved display device has a force that causes the display panel 82 to return to the original planar shape, that is, stress in a direction in which the protective plate 81 and the display panel 82 are peeled off as shown in FIG. 84 occurs. When the stress 84 exceeds the adhesive strength of the OCA 83, the bonding portion is peeled off. Bubbles are generated in the peeling region, and the yield in the manufacturing process of the curved display device is reduced. In order to avoid such a problem, there is a method of manufacturing a curved display device in which the thickness of the display panel 82 is made thinner than before and the stress 84 is relaxed. However, in such a manufacturing method, the strength of the display panel 82 is reduced, and the display panel 82 is cracked or chipped.

  FIG. 13B is a cross-sectional view showing a conventional curved display device in which the display panel 82 is bonded to the concave surface of the curved protective plate 81 in the same manner as described above. The sticking of the protection plate 81 shown in FIG. 13B to the concave surface is more difficult than the sticking to the convex surface. Before the display panel 82 is attached to the protective plate 81, the display panel 82 needs to be bent more than the protective plate 81. For this reason, the load applied to the display panel 82 is larger than that when the display panel 82 is attached to the convex surface. In the bonding process, the display panel 82 is cracked or chipped, resulting in a problem of yield reduction.

  The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a curved display device that reduces a residual stress generated between a curved protective plate and a display panel.

  A curved display device according to the present invention includes a display panel and a curved plate-shaped protective housing that encloses a curved sheet-like internal space and surrounds the internal space, and the protective housing is part of the outer periphery. The display panel is disposed in the internal space, including an opening that communicates the internal space with the outside of the protective housing.

  According to the curved display device of the present invention, it is possible to provide a curved display device that reduces the residual stress generated between the curved protective plate and the display panel.

3 is a diagram showing a curved display device in Embodiment 1. FIG. 3 is a diagram illustrating a protective housing included in the curved display device in Embodiment 1. FIG. 3 is a diagram showing a display panel included in the curved display device in Embodiment 1. FIG. 3 is a flowchart showing a method for manufacturing the curved display device in the first embodiment. FIG. 6 shows a method for manufacturing the curved display device in the first embodiment and the second embodiment. FIG. 10 is a diagram showing a curved display device in a second embodiment. 10 is a flowchart showing a method for manufacturing the curved display device in the second embodiment. FIG. 10 shows a curved display device in a third embodiment. 10 is a flowchart showing a method of manufacturing the curved display device in the third embodiment. It is a figure which shows the manufacturing method of the curved display apparatus in Embodiment 3. FIG. 10 is a flowchart showing a method of manufacturing the curved display device in the fourth embodiment. It is a figure which shows the manufacturing method of the curved display apparatus in Embodiment 4. FIG. It is sectional drawing which shows the structure of the conventional curved display apparatus.

  Embodiments of a curved display device and a manufacturing method thereof according to the present invention will be described.

<Embodiment 1>
(Configuration of curved display device)
FIG. 1A is a perspective view showing the curved display device according to the first embodiment. FIG.1 (b) is sectional drawing between AA 'of the curved display apparatus shown to Fig.1 (a). The curved display device according to the first embodiment includes a curved plate-shaped protective housing 10 that encloses a curved sheet-like internal space 30 and surrounds the internal space 30, and a display panel 20 that is disposed in the internal space 30. With. Further, the protective casing 10 includes an opening 31 that communicates the internal space 30 and the outside of the protective casing 10 on one side thereof. In FIG. 1A and FIG. 1B, illustration of a backlight or the like that is a light source for illuminating the display panel 20 is omitted.

  First, the configuration of the protective housing 10 included in the curved display device will be described. FIG. 2A is a perspective view showing the protective housing 10. FIG. 2B is a cross-sectional view of the protective housing 10 between B and B ′ shown in FIG. As described above, the protective housing 10 includes the curved thin plate-like internal space 30 and includes the opening 31 that connects the internal space 30 and the outside of the protective housing 10 on one side. The protective housing 10 of the first embodiment has a curved plate-like box shape, and is an integral body integrally molded from the same material. The internal space 30 curved into a sheet shape included in the protective housing 10 is sandwiched between two protective plates 10a and 10b that form the protective housing 10 that is an integrally molded product. Each protection plate has a shape with a radius of curvature of 800 mm and a plate thickness of 2 mm, and the distance between the protection plates is 2 mm. From the viewpoint of mechanical strength, the thickness of each protective plate is preferably 1 mm or more. Further, from the viewpoint of the product weight and the total product thickness of the curved display device, the thickness of each protective plate is preferably 5 mm or less.

  In the first embodiment, the material of the protective housing 10 is an acrylic resin. However, the material is not limited to the acrylic resin, and a transparent resin having a transmittance of 80% or more in the visible light region may be used. Since the protective housing 10 has a transmittance of 80% or more in the visible light region, it is possible to reduce deterioration in display quality of the curved display device due to the protective housing 10. In particular, the in-plane region (not shown) of the protective plate 10a or the in-plane region (not shown) of the protective plate 10b facing the display region (not shown) of the display panel 20 has a visible light transmittance of 80. % Or more is desirable. On the other hand, it is desirable that the protective housing 10 facing the other part of the display area of the display panel 20, for example, the frame area (not shown) of the display panel 20, is better to hide by black printing or the like. The black printing is preferably performed at the time of molding the protective housing 10, for example.

  Next, the configuration of the display panel 20 provided in the curved display device will be described. FIG. 3A is a perspective view showing the display panel 20. 3A is connected to a flexible printed circuit (FPC) 23. The display panel 20 shown in FIG. FIG. 3B is a cross-sectional view of the display panel 20 between C-C ′ shown in FIG. The display panel 20 includes a substrate 21a and a substrate 21b arranged to face each other, and further includes a polarizing plate 22a and a polarizing plate 22b on the outer sides of both the substrates. In the first embodiment, the thickness of the display panel 20 is 1.5 mm. The display panel 20 is a liquid crystal panel, for example. Note that in FIG. 3B, illustration of a display element or the like provided between two substrates is omitted.

  The curved display device according to the first embodiment shown in FIGS. 1 (a) and 1 (b) has a curved internal space 30 enclosed in the protective housing 10 shown in FIG. 2 (a). The display panel 20 illustrated in FIG. The internal space 30 has a size capable of containing the display panel 20, and the opening 31 has a size capable of inserting the display panel 20. The thickness of the internal space 30, that is, the inter-plate distance 30 a between the protective plate 10 a and the protective plate 10 b constituting the protective housing 10 is larger than the panel thickness 20 a of the display panel 20. There is a gap between the two. In the first embodiment, the inter-plate distance 30a of the internal space 30 is 2 mm, and the panel thickness 20a of the display panel 20 is 1.5 mm.

  Further, the protective housing 10 has higher plasticity than the display panel 20. Therefore, the curvature of the display panel 20 according to the first embodiment is formed by supporting at least a part of the display panel 20 in the internal space 30 by the protective plate 10a or the protective plate 10b.

  The entire surface on one side of the display panel 20 shown in FIG. 1 (b) is in contact with the protective plate 10b of the protective housing 10, but the entire surface on one side of the display panel 20 is thus attached to either the protective plate 10a or the protective plate 10b. There is no need to touch. The radius of curvature of the display panel 20 disposed in the internal space 30 may be a value different from the radius of curvature of the protective plate 10a or the protective plate 10b. When the radius of curvature of the display panel 20 is larger than the radius of curvature of the protective plate 10a or the protective plate 10b, the central side of the display panel 20 is a protective plate 10a located on the inner side of the two curved protective plates in a cross-sectional view. The both ends of the display panel 20 are in contact with the protective plate 10b, and the curvature of the display panel 20 is formed. That is, the curved display device according to the first embodiment can disperse the stress generated between the display panel 20 and the protective plate described above on the two protective plates.

(Method of manufacturing curved display device)
A method of manufacturing the curved display device in the first embodiment will be described. FIG. 4 is a flowchart showing a method of manufacturing the curved display device in the first embodiment. First, a protective housing 10 is prepared which includes a curved sheet-like internal space 30 and encloses the internal space 30 and includes an opening 31 which communicates the internal space 30 and the outside on one side (step S10). In the first embodiment, as shown in FIG. 2, a protective housing 10 is prepared in which an opening 31 is provided in a size that allows the display panel 20 to be inserted, and is integrally molded. Further, the internal space 30 has a size capable of containing the display panel 20. Specifically, as shown in FIG. 1B, for a display panel 20 having a panel thickness 20a of 1.5 mm, the inter-plate distance 30a of the protective housing 10, that is, the height of the opening is 2 mm, the radius of curvature. A box-shaped protective housing 10 surrounding a curved sheet-like internal space 30 of 800 mm is prepared. After step S10, the display panel 20 is arranged in the internal space 30 (step S20). In the first embodiment, as shown in FIG. 5, the display panel 20 is disposed by being inserted into the internal space 30 through the opening 31. Details of the insertion step will be described. First, the display panel 20 is supported by a jig (not shown) having a curvature radius of 800 mm. Thereby, the display panel 20 is curved. The display panel 20 curved by the jig is inserted into the internal space 30 through the opening 31 in the curved state, and is released from the jig in parallel with the insertion operation. The display panel 20 is disposed in the internal space 30 through the above steps.

  Although not shown after step S20, a backlight serving as a light source is attached to the side opposite to the display surface included in the display panel 20, and the curved display device is completed (step S80).

  In the first embodiment, the inter-plate distance 30a of the protective housing 10 is 2 mm, and the panel thickness 20a of the display panel 20 is 1.5 mm. By reducing the panel thickness 20a of the display panel 20, for example, It is also possible to manufacture a curved display device with an inter-plate distance 30a of 1 mm. Manufacturing the curved display device using the protective housing 10 having a small inter-plate distance 30a is further preferable because the total thickness of the curved display device is reduced. However, when the inter-plate distance 30a is 0.5 mm or less, it is necessary to manufacture the display panel 20 having a panel thickness 20a of 0.4 mm or less. Since it is difficult to manufacture such a thin display panel 20, the lower limit of the inter-plate distance 30a is preferably 0.6 mm.

  On the other hand, in the above manufacturing method, the larger the difference between the inter-plate distance 30 a of the protective housing 10 and the panel thickness 20 a of the display panel 20, the easier the insertion of the display panel 20 into the internal space 30. However, when the inter-plate distance 30a is 5 mm or more, the gap between each protection plate and the display panel 20 becomes large. Therefore, the inter-plate distance 30a is preferably 4 mm or less.

(effect)
In summary, the curved display device according to the first embodiment includes the display panel 20 and a curved plate-shaped protective housing 10 that encloses the curved sheet-like internal space 30 and surrounds the internal space 30. The protective housing 10 includes an opening 31 that communicates the internal space 30 and the outside of the protective housing 10 on one side, and the display panel 20 is disposed in the internal space 30. With the configuration as described above, the curved display device can reduce the residual stress generated between each protective plate that shapes the curvature of the display panel 20 and the display panel, particularly the stress in the direction of peeling each other. In addition, the curved display device according to the first embodiment makes it possible to manufacture a curved display device including the display panel 20 in the curved internal space 30 as described above.

  In addition, the opening 31 of the curved display device according to the first embodiment is provided with a size that allows the display panel 20 to be inserted, and the protective housing 10 is an integrally molded unit. With the configuration described above, the curved display device can provide a method for manufacturing a curved display device including the curved display panel 20 by simply placing the display panel 20 in the internal space 30 surrounded by the protective housing 10. To do.

  In addition, the display panel 20 of the curved display device according to the first embodiment includes a display area for displaying a video or an image, and at least the area facing the display area is transparent in the protective housing 10 of the curved display device. With the configuration described above, the protective housing of the curved display device does not hinder the display of video or images on the display panel 20.

  In addition, the material of the protective housing 10 of the curved display device according to the first embodiment includes a resin. With the above-described configuration, the curved display device can include the protective housing 10 having a box shape formed by integrally molding resin.

  Further, the radius of curvature of the protective housing 10 of the curved display device according to the first embodiment is 300 mm or more and 2000 mm or less. With the configuration as described above, the curved display device can include the display panel 20 curved by the protective housing 10 in the internal space 30.

  Further, in the manufacturing method of the curved display device according to the first embodiment, the curved sheet-like internal space 30 is enclosed so as to surround the internal space 30, and the opening 31 that connects the internal space 30 and the outside to a part of the outer periphery. And a step of preparing a curved plate-shaped protective housing 10 including the step of disposing the display panel 20 in the internal space 30. With the configuration as described above, the method for manufacturing the curved display device according to the first embodiment does not require a step of attaching the display panel 20 to the curved protective plate with a strong pressure as in the conventional technique. For example, it is possible to reduce the load on the display panel 20 that has been conventionally applied in the process of attaching the display panel 20 to the concave surface of the protective plate, which has been difficult to attach. As a result, the method of manufacturing the curved display device according to the first embodiment can reduce the occurrence of cracks in the display panel 20 in the manufacturing process, and improve the yield of the curved display device.

  Further, in the method of manufacturing the curved display device according to the first embodiment, in the step of preparing the protective housing 10, the opening 31 is provided in a size that can be inserted through the display panel 20, and is integrally formed. The step of preparing a protective housing 10 and arranging the display panel 20 includes inserting the display panel 20 through the opening 31 and arranging the display panel 20 in the internal space 30. With the above-described configuration, the method for manufacturing the curved display device according to the first embodiment can manufacture the curved display device by simply inserting the display panel 20 into the curved internal space 30 from the opening 31. Since the manufacturing method is easy, the yield in the manufacturing process of the curved display device can be improved.

<Embodiment 2>
A curved display device and a manufacturing method thereof according to the second embodiment will be described. Note that the description of the same configuration and operation as in the first embodiment will be omitted.

(Configuration of curved display device)
FIG. 6 is a cross-sectional view of the curved display device according to the second embodiment. The curved display device includes the display panel 20 and the protective housing in the internal space 30 shown in FIGS. 1 (a) and 1 (b). 10 is further provided with a transparent resin material 32. The transparent resin material 32 is filled and arranged so as to cover the display panel 20. The curved display device described in the first embodiment includes a gap between the display panel 20 and each protection plate. However, in the curved display device according to the second embodiment, the gap is filled with a transparent resin material. Therefore, the curvature of the display panel 20 can be stably held. In addition, the display panel 20 is supported by the protection plate 10 a, the protection plate 10 b, and the transparent resin material 32 inside the internal space 30 to form a curve.

  The refractive index of the transparent resin material 32 is preferably 1.1 or more and 2.5 or less. When an air layer is present between the display panel 20 and the protective housing 10, light is reflected at the interface between the display panel 20 and the air layer or the interface between the air layer and the protective housing 10. Therefore, the air layer is replaced with a transparent resin material 32 having a refractive index close to that of the material of the protective housing 10. Since the protective casing 10 has a refractive index of 1.1 or more, it is desirable to select a transparent resin material 32 having a refractive index of 1.1 or more and 2.5 or less. More preferably, the transparent resin material 32 is a material having a refractive index ± 0.1 of the material of the protective housing 10. In the second embodiment, the transparent resin material 32 is an acrylic resin.

(Method of manufacturing curved display device)
A method for manufacturing the curved display device according to the second embodiment will be described. FIG. 7 is a flowchart showing a method for manufacturing the curved display device of the second embodiment. The manufacturing method of the curved display device of the second embodiment is the same as the manufacturing method described in the first embodiment until step S20. After step S20, the transparent resin material 32 is filled into the internal space 30 described in FIG. 1A from the opening 31 (step S30). In step S30, the transparent resin material 32 is preferably a liquid resin, which facilitates filling. In the second embodiment, the transparent resin material 32 is a liquid acrylic resin having ultraviolet (UV) curing characteristics. The transparent resin material 32 may be a thermosetting resin. The transparent resin material 32 may be OCLA (Optical Clear Liquid Adhesive).

  After step S30, the protective casing 10 is left under reduced pressure, so that bubbles generated from the transparent resin material 32 are removed from the protective casing 10 (step S40). In the second embodiment, the protective casing 10 is left in a -85 kPa decompression device for about 1 hour to defoam bubbles contained in the transparent resin material 32. At this time, the generated bubbles are degassed from the opening 31.

  After step S40, the transparent resin material 32 is cured (step S50). In the second embodiment, the transparent resin material 32 is cured by irradiating the transparent resin material 32 with UV light from the outside of the protective housing 10. By curing the transparent resin material 32, the mechanical strength of the curved display device is increased. Further, the generation of bubbles is reduced from the cured transparent resin material 32. For example, when a high temperature storage test was performed in which the transparent resin material 32 was not cured and was left in a liquid state in an environment of 70 ° C. for 1000 hours, bubbles were generated from the transparent resin material 32. On the other hand, when the transparent resin material 32 is irradiated with UV light of 2000 mJ to 10000 mJ to cure the transparent resin material 32, the transparent resin material 32 is exposed to the transparent resin material 32 even after a high-temperature storage test in which the transparent resin material 32 is left for 1000 hours in an environment of 95 ° C. No bubbles were generated, and good results were obtained.

  When the material constituting the protective housing 10 is a material that does not transmit UV light, a thermosetting liquid resin is filled as the transparent resin material 32 in step S20. The thermosetting liquid resin desirably has a property of being cured at, for example, 90 ° C. or less. This is because if the transparent resin material 32 can be cured at a temperature of 90 ° C. or lower in step S40, deterioration of each polarizing plate of the display panel 20 and the protective housing 10 can be prevented. In the second embodiment, an acrylic resin is used for the transparent resin material 32. However, a silicon resin or a two-component mixed curable resin may be used.

  Although illustration is omitted after step S50, a backlight is attached to the opposite side of the display surface of the display panel 20 as in the first embodiment, and the curved display device is completed (step S80).

(effect)
In summary, the curved display device according to the second embodiment further includes a transparent resin material 32 filled between the display panel 20 provided in the internal space 30 and the protective housing 10. With the above configuration, the mechanical strength of the curved display device is improved, and the curvature of the display panel 20 is also stabilized.

  Further, the refractive index of the transparent resin material 32 of the curved display device of the second embodiment is 1.1 or more and 2.5 or less. With the configuration as described above, the external light reflection characteristics of the curved display device can be improved, and the appearance of the video or image is improved.

  The method for manufacturing the curved display device according to the second embodiment further includes a step of filling the internal space 30 with the transparent resin material 32 from the opening 31. With the configuration as described above, the method for manufacturing the curved display device can easily fill the internal space 30 with the transparent resin material 32.

  Further, in the method of manufacturing the curved display device according to the second embodiment, the step of leaving the protective housing 10 under reduced pressure to degas bubbles contained in the transparent resin material 32 and the step of curing the transparent resin material 32 are performed. And further comprising. With the configuration as described above, the method for manufacturing the curved display device can reduce bubbles from the transparent resin material 32 generated by the stress that the display panel 20 tries to return to the original flat plate shape in the internal space 30. As a result, the yield in the manufacturing process of the curved display device is improved.

<Embodiment 3>
A curved display device and a manufacturing method thereof according to Embodiment 3 will be described. Note that the description of the same configuration and operation as those of the first and second embodiments is omitted.

(Configuration of curved display device)
FIG. 8A is a perspective view showing a curved display device according to the third embodiment. FIG.8 (b) is sectional drawing between DD 'of the curved display apparatus shown to Fig.8 (a). In addition, illustration of the backlight etc. which are the light sources which illuminate the display panel 20 is abbreviate | omitted. The protective casing 10 of the curved display device according to the third embodiment includes two curved protective plates 10a and 10b that are arranged to face each other, and a sealing material 10c that seals the outer periphery excluding the opening 31. including. Moreover, the opening 31 of the protective housing 10 is provided on one side from which the sealing material 10c is removed. With the above configuration, the internal space is surrounded by the protection plate 10a, the protection plate 10b, and the sealing material 10c. The protective housing 10 included in the curved display device described in the first embodiment is a box-shaped integrated body that surrounds the internal space 30, but the protective housing 10 of the curved display device according to the third embodiment has 2 The structure which sealed the outer periphery of the protection plate 10a and the protection plate 10b of the sheet | seat with the sealing material 10c is included. In addition, the opening 31 according to the third embodiment is provided on one side of the protective housing 10, but is not limited to this configuration, and the opening may be provided in a part of the outer periphery of the protective housing 10. In addition, the material of each protection board of this Embodiment 3 is glass, and a sealing material is UV curable resin.

  As shown in FIGS. 8A and 8B, the display panel 20 of the curved display device according to the third embodiment has a curved internal space 30 that includes the curved plate-shaped protective housing 10. Placed in. The curved display device further includes a transparent resin material 32 filled between the display panel 20 provided in the internal space 30 and the protective housing 10 as in the second embodiment. The transparent resin material 32 is a UV curable resin. For example, the transparent resin material 32 is OCLA.

(Method of manufacturing curved display device)
A method for manufacturing the curved display device according to the third embodiment will be described. FIG. 9 is a flowchart showing a method of manufacturing the curved display device in the third embodiment. In the third embodiment, the process of preparing the protective housing 10 in step S10 includes two processes. One of them is a step (step S10a) in which two curved protective plates 10a and 10b are arranged to face each other, and the other is to seal the outer periphery excluding one side of each protective plate with a sealing material 10c. In this step, the opening 31 and the internal space 30 are formed (step S10b). Further, in the third embodiment, the process of arranging the display panel in the internal space is a process of arranging the display panel 20 between the protective plate 10a and the protective plate 10b arranged to face each other as shown in FIG. Step S20a) is performed between Step S10a and Step S10b described above.

  A method of manufacturing the curved display device according to the third embodiment including the above steps will be described in chronological order. As shown in FIG. 9, first, the two protection plates 10a and 10b that are curved are arranged to face each other (step S10a). The display panel 20 is placed and sandwiched between the protective plate 10a and the protective plate 10b that are arranged to face each other (step S20a). Except for one side of each protection plate, the outer periphery thereof is sealed with a sealing material 10c to form the opening 31 and the internal space 30 (step S10b). Further, since the display panel 20 is arranged in the internal space 30 by step S10b, step S10b of the third embodiment includes a part of the process of arranging the display panel 20 in the internal space 30. After step S10b, as shown in FIG. 8B, the curved display device includes a gap (air layer) between each protection plate and the display panel 20. Therefore, the process from step S20a to step S10b is performed so that the inter-plate distance 30a larger than the panel thickness 20a of the display panel 20 is provided. In the third embodiment, the panel thickness 20a of the display panel 20 is 1.5 mm, and the distance 30a between the two protective plates is 2 mm. Each protection plate has a shape with a radius of curvature of 800 mm, and the material thereof is glass excellent in weather resistance. The display panel 20 is curved by the processes from step S20a to step S10b.

  In the method of manufacturing the curved display device according to the third embodiment, after step S10b, the transparent resin material 32 is filled into the internal space 30 from the opening 31 at step S30, and the defoaming of the transparent resin material 32 is performed at step S40. In step S50, the transparent resin material 32 is cured. The transparent resin material 32 is a liquid UV curable resin, and is cured by irradiating the transparent resin material 32 with UV light from the outside of the protective housing 10. In the third embodiment, since glass that easily transmits UV light is used for the protective plate 10 a and the protective plate 10 b of the protective housing 10, an inexpensive UV curable resin can be used for the transparent resin material 32.

  Through the above steps, the display panel 20 is supported by the protective housing 10 or the transparent resin material 32, whereby the display panel 20 is curved. Further, after step S50, although not shown, a backlight is attached to the opposite side of the display surface of the display panel 20, and the curved display device is completed (step S80).

  In the third embodiment, the curved inner space is formed by two curved protective plates. However, two or more curved protective plates are connected to each other to make the curved display device more complicated than the curved display device of the third embodiment. It is also possible to produce a protective housing that encloses an internal space having a curved shape. Further, it is possible to manufacture a curved display device having a complicated curve in which a display panel is arranged in an internal space formed by the two or more curved protective plates.

(effect)
In summary, the protective housing 10 of the curved display device according to the third embodiment seals the outer periphery excluding two curved protective plates 10a and 10b arranged opposite to each other and the opening 31. The internal space 30 is surrounded by the protective plates and the sealing material 10c. With the configuration as described above, the curved display device can reduce the residual stress generated between each protective plate that shapes the curvature of the display panel 20 and the display panel, particularly the stress in the direction of peeling each other. In addition, the curved display device according to the third embodiment is capable of manufacturing a curved display device including a curved display panel 20 by simply placing the display panel 20 in the internal space 30 surrounded by the protective housing 10. Is realized. Moreover, although it is difficult to manufacture the protective casing 10 of the integrally molded product included in the curved display device described in the first embodiment or the second embodiment using glass as a material, the above-described protection unit 10 described in the third embodiment is used. According to the configuration, it is possible to provide a curved display device using a glass protective plate for the protective housing 10.

  The material of the protective housing of the curved display device according to the third embodiment includes glass. With the configuration as described above, the protective housing of the curved display device according to the third embodiment does not hinder the display of images or images on the display panel 20. Moreover, since glass is excellent in weather resistance, the curved display device provided with the glass protective housing 10 has high reliability. Further, since the protective housing 10 is made of glass, an inexpensive UV curable resin can be used for the transparent resin material 32.

  In addition, the step of preparing the protective housing 10 of the method for manufacturing the curved display device according to the third embodiment includes the steps of preparing two curved protective plates 10a and 10b, and one outer periphery of the protective plate. Including the step of forming the opening 31 and the internal space 30 by sealing with the sealing material 10c except for the portion, and the step of arranging the display panel 20 in the internal space 30 includes the step of preparing the protective plate described above Between the step of forming the opening 31 and the internal space 30, the display panel 20 is disposed between the two protective plates. With the configuration as described above, the method for manufacturing the curved display device according to the third embodiment does not require a step of bonding the display panel 20 to the curved protective plate with a strong pressure unlike the prior art. In the manufacturing method of the curved display device of the first embodiment, the generation of cracks in the display panel 20 can be reduced in the manufacturing process, and the yield of the curved display device is improved. In addition, the method for manufacturing the curved display device according to the third embodiment does not require the protective housing 10 integrally molded into a box shape as in the first embodiment. In the method of manufacturing the curved display device according to the third embodiment, two curved protective plates are prepared, and the display panel 20 is simply sandwiched between the protective plates. Therefore, the curved display device can be manufactured at low cost. . In addition, the method of manufacturing the curved display device according to the third embodiment is easier and lower in comparison with the manufacturing method in which the display panel 20 is inserted into the protective housing 10 in which the width of the opening 31, that is, the inter-plate distance 30a is small. Cost can be reduced.

<Embodiment 4>
A method for manufacturing the curved display device in the fourth embodiment will be described. In addition, description is abbreviate | omitted about the structure similar to the curvature display apparatus in any one of Embodiment 1 to Embodiment 3, and its manufacturing method.

  According to the method for manufacturing a curved display device described in any of the first to third embodiments, the display panel 20 is disposed in the curved sheet-like internal space 30 surrounded by the protective housing 10. Therefore, the in-plane size of the internal space 30 needs to be larger than the in-plane size of the display panel 20. For example, in the method of manufacturing the curved display device described in the first embodiment or the second embodiment, the display panel 20 is inserted into the internal space 30 through the opening 31 as shown in FIG. At that time, the position where the display panel 20 is inserted into the opening 31 may be shifted due to an error in the manufacturing process. In consideration of the error, a clearance of 1 mm is provided in advance between the outer periphery of the internal space 30 and the outer periphery of the display panel 20, that is, in each of the vertical direction and the horizontal direction. That is, the width of the opening 31 of the protective housing 10 is 2 mm larger than the width of the display panel 20. As a result, in the curved display device manufactured by the method for manufacturing the curved display device described in the first embodiment or the second embodiment, the relative position of the display panel 20 with respect to the outer edge of the protective housing 10 is ± for each curved display device. 1mm may be different.

  The same applies to the curved display device manufactured by the method for manufacturing the curved display device described in the third embodiment. In step S20a of the third embodiment, the display panel 20 is disposed and sandwiched between the protective plate 10a and the protective plate 10b as shown in FIG. Due to manufacturing errors in the process, the relative position of the display panel 20 with respect to the outer edge of the protective housing 10 may be different for each curved display device.

  Therefore, in the method for manufacturing a curved display device according to the fourth embodiment, a protective casing having a larger outer size than the outer size of the protective casing included in the finally completed curved display device is prepared and the first embodiment starts. A curved display device is manufactured by any one of the manufacturing methods of Embodiment Mode 3. Thereafter, the outer periphery of the protective housing is polished, and the outer size is aligned with the final finished product. Hereinafter, an example of the manufacturing method will be described.

  FIG. 11 is a flowchart showing a method of manufacturing the curved display device in the fourth embodiment. In step S10, a protective housing having an outer size larger than the outer size of the protective housing included in the curved display device that is finally completed is prepared. In the fourth embodiment, a protective casing in which the outer circumference of the protective casing is 3 mm wider than the design value is used. Subsequently, the manufacturing process of the curved display device up to step S50 described in the second embodiment is performed. FIG. 12A is a perspective view of the curved display device in which the display panel 20 is arranged in the internal space 30 enclosed in the protective housing 10 whose outer size is larger than the final finished product. After step S50, the position of the display panel 20 relative to the outer edge of the protective housing 10 is recognized by image processing. The polishing amount of each side of the protective housing 10 is calculated so that the relative position of the display panel 20 with respect to the outer edge of the protective housing 10 matches the design value of the finished product on any side (step S60). The outer periphery of the protective housing 10 is polished based on the polishing amount. (Step S70). FIG. 12B is a perspective view showing a curved display device including the protective housing 10 in which the polishing margin 11 based on the calculated polishing amount is polished. A curved display device having a relative positional accuracy of ± 0.2 mm between the protective housing 10 and the display panel 20 can be manufactured. After step S70, as in the other embodiments, a backlight (not shown) is attached to the side opposite to the display surface of the display panel 20, and the curved display device is completed (step S80).

  The polishing margin 11 preferably has a width of 1 mm to 5 mm. Because of the relative positional accuracy between the protective housing 10 and the display panel 20, the polishing margin 11 needs to be at least 1 mm wide. On the other hand, if the polishing margin 11 exceeds 6 mm in width, the polishing cost increases. Accordingly, the polishing margin 11 preferably has a width of 1 mm to 5 mm.

  In summary, the method of manufacturing the curved display device according to the fourth embodiment further includes a step of polishing the outer periphery of the protective housing 10. With the configuration as described above, it is possible to provide a curved display device in which the relative positional accuracy between the protective housing 10 and the display panel 20 is improved. In the fourth embodiment, the method for manufacturing a curved display device having a rectangular shape in plan view has been described. However, the method can be easily applied to a method for manufacturing an irregular curved display device such as a circular shape. Even when the protective plate is atypical and curved, according to the method of manufacturing the curved display device of the fourth embodiment, the curved protective casing is simply polished according to the design shape, so that the curved display is displayed. The degree of freedom in designing the product of the device and the manufacturing process is improved. Further, the manufacturing cost can be reduced.

  It should be noted that the present invention can be freely combined with each other within the scope of the invention, and each embodiment can be appropriately modified or omitted.

  10 protective casing, 10a protective plate, 10b protective plate, 10c sealing material, 11 polishing margin, 20 display panel, 20a panel thickness, 30 internal space, 30a distance between plates, 31 opening, 32 transparent resin material.

Claims (14)

A display panel;
Including a curved sheet-like internal space, and a curved plate-shaped protective housing surrounding the internal space,
The protective housing includes an opening that communicates the internal space with the outside of the protective housing in part of the outer periphery;
The curved display device, wherein the display panel is disposed in the internal space. The opening is provided in a size that allows the display panel to be inserted;
The curved display device according to claim 1, wherein the protective housing is an integrally molded body. The protective housing is
Two curved protective plates arranged facing each other;
A sealing material for sealing the outer periphery excluding the opening,
The curved display device according to claim 1, wherein the internal space is surrounded by the protective plates and the sealing material.   The curved display device according to claim 1, further comprising a transparent resin material filled between the display panel provided in the internal space and the protective housing.   The curved display device according to claim 4, wherein a refractive index of the transparent resin material is 1.1 or more and 2.5 or less. The display panel includes a display area for displaying a video or an image,
The curved display device according to any one of claims 1 to 5, wherein at least a region facing the display region is transparent in the protective housing.   The curved display device according to any one of claims 1 to 6, wherein a material of the protective housing includes glass or resin.   The curvature display device according to any one of claims 1 to 7, wherein a radius of curvature of the protective housing is 300 mm or more and 2000 mm or less. Preparing a curved plate-shaped protective housing containing an opening that encloses the curved internal space and encloses the internal space, and includes an opening that communicates the internal space and the outside in part of the outer periphery;
And a step of arranging a display panel in the internal space. In the step of preparing the protective casing, the opening is provided in a size that allows the display panel to be inserted therethrough, and the protective casing that is an integrally molded article is prepared.
The method of manufacturing a curved display device according to claim 9, wherein the step of disposing the display panel includes disposing the display panel through the opening and disposing the display panel in the internal space. The step of preparing the protective housing includes
Arranging two curved protective plates facing each other;
Sealing the space between the protective plates except for a part of the outer periphery of the protective plate with a sealing material to form the opening and the internal space,
The step of disposing the display panel in the internal space includes disposing the display panel between the two protective plates between the step of preparing the protective plate and the step of forming the opening and the internal space. The manufacturing method of the curved display apparatus of Claim 9 including doing.   The method of manufacturing a curved display device according to claim 9, further comprising a step of filling the internal space with a transparent resin material from the opening. Leaving the protective housing under reduced pressure to degas bubbles contained in the transparent resin material;
The method for manufacturing a curved display device according to claim 12, further comprising a step of curing the transparent resin material.   The method of manufacturing a curved display device according to claim 9, further comprising a step of polishing an outer periphery of the protective housing.

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