JP6561474B2 - Method for manufacturing flexible display device - Google Patents

Description

  The present invention relates to a method for manufacturing a flexible display device.

  In recent years, with the rapid spread of flat displays such as liquid crystal displays (liquid crystal display devices), organic LEDs (organic light-emitting-diodes), and electronic paper displays, the demand for display members constituting such displays has increased. ing. Current flat panel displays are widely used not only for TVs and desktop monitors, but also for portable electronic devices such as portable notebook computers, mobile phones, portable game consoles, electronic readers, and electronic books. For this reason, further weight reduction, size reduction, and thickness reduction are required.

  In such a situation, as a display member constituting a liquid crystal display, an organic LED display, an electronic paper display or the like, a flexible base made of a flexible film is used instead of the glass base which has been mainly used so far. The display member used has been proposed. By using a flexible substrate instead of a glass substrate in the display member, the display can be a flexible display. Actually, as such a flexible display, for example, a transparent touch panel, a liquid crystal display, an organic EL display, and the like are known.

  However, the flexible base material has a problem that the flexible base material is distorted when the display member is manufactured using the flexible base material because the mechanical strength is lower than that of the conventional glass base material. . In order to solve this problem, for example, it is disclosed that a stress relaxation hole is provided in a flexible base material as disclosed in Patent Document 1.

  Or in order to improve productivity, while conveying a pair of strip | belt-shaped flexible laminated body wound up by the roll, and joining this pair of flexible laminated body, the technique of adjusting the distortion | strain of a flexible base material is also developed ( Patent Document 2).

JP 2009-36859 A JP 2013-72964 A

  However, even with any of the above technologies, the flexible base material is strained and formed on the flexible base material, particularly when the other flexible base material is bonded to the flexible base material on which the pattern is formed by the adhesive layer. There is a problem that the dimensional accuracy of the pattern decreases.

  The present invention has been made in consideration of such points, and provides a method for manufacturing a flexible display device capable of improving the dimensional accuracy of a display unit formed in a pattern on a flexible substrate. With the goal.

  In the method for manufacturing a flexible display device, the present invention provides a step of manufacturing a belt-shaped first carrier-attached base material by joining the belt-shaped first carrier and the belt-shaped first substrate, and the first carrier-attached base. A step of providing the first display portion on the material to produce a strip-shaped first carrier-attached display portion, and joining the strip-shaped second carrier and the strip-shaped second base material to form the strip-shaped base material with the second carrier. A step of producing, a step of providing a second display portion on the base material with the second carrier to produce a strip-shaped display portion with the carrier, the base material with the first carrier and the base material with the second carrier. Bonding the first carrier and the second carrier so that the second carrier faces outward, and producing at least one of the first carrier and the second carrier from the carrier-equipped display device. Peel to obtain a flexible display device A method of manufacturing a flexible display device characterized by comprising: a step.

  The present invention is the method for manufacturing a flexible display device, wherein the first carrier has higher heat resistance than the first base material, and the second carrier has higher heat resistance than the second base material.

  The present invention is the method for manufacturing a flexible display device, wherein the first carrier has a larger film thickness than the first substrate, and the second carrier has a larger film thickness than the second substrate.

  In the method for manufacturing a flexible display device, the present invention provides a step of manufacturing a belt-shaped first carrier-attached base material by joining the belt-shaped first carrier and the belt-shaped first substrate, and the first carrier-attached base. A step of providing the first display portion on the material to produce a strip-shaped first carrier-attached display portion, and joining the strip-shaped second carrier and the strip-shaped second base material to form the strip-shaped base material with the second carrier. A step of manufacturing, a step of providing a second display portion on the base material with the second carrier to produce a strip-shaped display portion with a carrier, and joining the strip-shaped third carrier and the strip-shaped third base material. A step of producing a strip-shaped base material with a third carrier, a step of providing a third display portion on the base material with the third carrier to produce a strip-shaped base portion with a carrier, and the first carrier. The base material with the second carrier and the base material with the second carrier are the first carrier and the second carrier. Forming the carrier-attached display device by facing the side, peeling the first carrier from the first carrier-attached display portion, and placing the third carrier-attached display portion on the first display portion. A step of manufacturing a display device with an additional carrier by bonding the third carrier to face outward, and at least one of the second carrier and the third carrier is peeled from the display device with an additional carrier to be flexible. And a step of obtaining a display device. A method of manufacturing a flexible display device.

  In the present invention, the first carrier has greater heat resistance than the first substrate, the second carrier has greater heat resistance than the second substrate, and the third carrier has greater heat resistance than the second substrate. This is a method for manufacturing a flexible display device.

  In the present invention, the first carrier has a larger film thickness than the first substrate, the second carrier has a larger film thickness than the second substrate, and the third carrier has a larger film thickness than the third substrate. This is a method for manufacturing a flexible display device.

  As described above, according to the present invention, productivity can be improved and dimensional accuracy of a display unit formed in a pattern can be improved.

Drawing 1 is a figure showing the outline of the pasting device in the form for carrying out the present invention. FIG. 2 is a side sectional view showing the first carrier-equipped substrate. FIG. 3 is a side cross-sectional view showing a display unit with a first carrier. FIG. 4 is a diagram showing an outline of a bonding apparatus in an embodiment for carrying out the present invention. FIG. 5 is a side sectional view showing the second carrier-attached base material. FIG. 6 is a side sectional view showing a display unit with a second carrier. FIG. 7: is a figure which shows the outline of the bonding apparatus in the form for implementing this invention. FIG. 8 is a side sectional view showing the display device with a carrier. FIG. 9 is a side sectional view showing a flexible display device. FIG. 10 is a diagram showing an outline of a bonding apparatus in a modification. FIG. 11 is a side sectional view showing a third base material with a carrier in a modified example. FIG. 12 is a side cross-sectional view showing a third display unit with a carrier in a modified example. FIG. 13 is a diagram showing an outline of a sticking device in a modified example. FIG. 14 is a side sectional view showing an additional display device with a carrier in a modified example. FIG. 15 is a side sectional view showing a flexible display device according to a modification.

<Embodiment of the Invention>
Embodiments of the present invention will be described below with reference to the drawings.

  1 to 9 show an embodiment of the present invention.

  First, a flexible display device obtained by the method for manufacturing a flexible display device according to the present invention will be described with reference to FIG. In this embodiment, an organic LED (Light-Emitting-Diode) display device with a color filter will be described as an example of a flexible display device.

  As shown in FIG. 9, the organic LED 1 with a color filter includes a flexible transparent substrate (first substrate) 11 and a colored layer 15 provided on the inner surface (lower surface of FIG. 9) of the first substrate 11. An organic LED element 20 having a color filter 10, a flexible transparent base material (second base material) 21, and an organic LED layer 22 provided on the outer surface (upper surface in FIG. 1) of the second base material 21. I have.

  Further, the color filter 10 and the organic LED element 20 are joined by an adhesive layer 30 made of an optical elastic resin.

  Next, the color filter 10 of the organic LED display device 1 with a color filter will be described in detail.

  As shown in FIG. 9, the color filter 10 includes a flexible first base material 11 and a colored layer 15 provided on the inner surface of the first base material 11.

  The colored layer 15 is provided on the inner surface of the first base material 11 and includes an R colored layer 15R, a G colored layer 15G, a B colored layer 15B, and a black matrix 16 formed in a pattern. ing.

  In this case, as the colored layer 15R for R, the colored layer 15G for G, and the colored layer 15B for B, the organic LED layer 22 is composed of the organic LED layer 22R for R, the organic LED layer 22G for G, and for B as described later. Since the organic LED layer 22B is used, the low color rendering color layers 15R, 15G, and 15B can be used. Specifically, the colored layers 15R, 15G, and 15B having an NTSC ratio of about 50% can be used.

  Next, the organic LED element 20 will be described. As shown in FIG. 9, the organic LED element 20 includes a flexible second base material 21, a wiring 28 and an insulating layer 27 provided on the outer surface of the second base material 21 (upper surface in FIG. 9), And an organic LED layer 22 provided on the insulating layer 27.

  Among these, the organic LED layer 22 includes R, G, and B organic LED elements, that is, the R organic LED layer 22R, the G organic LED layer 22G, and the B organic LED layer 22B. Each of the R organic LED layer 22R, the G organic LED layer 22G, and the B organic LED layer 22B is partitioned by a partition wall 29. Moreover, the organic LED layer 22R for R, the organic LED layer 22G for G, and the organic LED layer 22B for B are formed in a pattern shape, and all are on the reflective electrode 23 provided in the 2nd base material 21 side, and the reflective electrode 23 on it. The light emitting layer 24 provided and the transparent electrode 25 made of ITO or the like provided on the light emitting layer 24 are included.

  The organic LED layer 22R for R, the organic LED layer 22G for G, and the organic LED layer 22B for B having such a configuration are covered with a protective layer 26.

  Next, components of the R organic LED layer 22R, the G organic LED layer 22G, and the B organic LED layer 22B will be described.

  The reflective electrode 23 also functions as a reflective layer, and it is desirable to increase the luminous efficiency to have as high a reflectance as possible. In particular, when the reflective electrode 23 is used as an anode, the reflective electrode 23 is preferably made of a material having a high hole injection property. As such a reflective electrode 23, for example, the thickness in the stacking direction (hereinafter simply referred to as thickness) is 100 nm or more and 1000 nm or less, and chromium (Cr), gold (Au), platinum (Pt), nickel (Ni). , Copper (Cu), tungsten (W), silver (Ag), or other elemental elements or alloys of metal elements. A transparent conductive film such as an oxide of indium and tin (ITO) may be provided on the surface of the reflective electrode 23. Appropriate hole injection is possible even in materials such as aluminum (Al) alloys that have a high reflectivity, but have a problem of the presence of an oxide film on the surface and a hole injection barrier due to a low work function. By providing a layer, it can be used as the reflective electrode 23.

  The light emitting layer 24 has, for example, a configuration in which a hole injection layer, a hole transport layer, a light emitter, an electron transport layer, and an electron injection layer are stacked in this order from the reflective electrode 23 side. Of these, layers other than the light emitter may be provided as necessary. The configuration of the light emitting layer 24 is different depending on the light emission colors of the R organic LED layer 22R, the G organic LED layer 22G, and the B organic LED layer 22B. The hole injection layer is a buffer layer for improving hole injection efficiency and preventing leakage. The hole transport layer is for increasing the efficiency of transporting holes to the light emitter. The light emitter emits light by recombination of electrons and holes when an electric field is applied. The electron transport layer is for increasing the efficiency of electron transport to the light emitter. The electron injection layer is for increasing electron injection efficiency.

  The transparent electrode 26 is made of a transparent material such as ITO.

The adhesive layer 30 is made of a transparent material such as an optical elastic resin. The adhesive layer 30 bonds the color filter 10 and the organic LED element 20, and the R organic LED layer 22R, the G organic LED layer 22G, and the B organic LED layer. 22B is covered and the function which protects these is performed.
As a material of the optical elastic resin layer, for example, commercially available OCA (Optically Clear Adhesive) or OCR (Optically Clear Resin) can be used.

  The organic LED layer 22R for R, the organic LED layer 22G for G, and the organic LED layer 22B for B are the colored layer 15R for R of the color filter 15 with the AR layer on the plane, and the colored layer 15G for G. It arrange | positions in the position corresponding to the colored layer 15B for use.

  Next, the material of each component will be described.

(1) Flexible first base material 11 and second base material 21
Next, the material of each flexible first base material 11 and second base material 21 will be described. Here, “flexible” means that there is flexibility, and “flexible substrate” generally means a substrate that is flexible and can be bent. The flexible first base material 11 and the second base material 21 in the present embodiment are not particularly limited as long as the plasticity is not extremely high even when a tension is applied. Can be appropriately selected and used. Examples of such flexible base materials 11 and 21 include polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polyethersulfone (PES), polyimide (PI), polyetheretherketone (PEEK), and polycarbonate. (PC), polyethylene (PE), polypropylene (PP), polyphenylene sulfide (PPS), polyetherimide (PEI), cellulose triacetate (CTA), cyclic polyolefin (COP), polymethyl methacrylate (PMMA), polysulfone (PSF) And synthetic resins such as polyamideimide (PAI), nobornene resin, and allyl ester resin. Of these, PEN and PET are preferably used.

  The thickness of the flexible base materials 11 and 21 is preferably in the range of 10 μm to 500 μm, and preferably in the range of 20 μm to 300 μm. This is because if the thickness of the flexible base materials 11 and 21 is too thick than the above range, the flexibility is impaired, the material is easily broken, and it is difficult to wind it into a roll shape. On the other hand, if it is thinner than the above range, there will be no strain and handling in the process will be difficult.

  Although it does not specifically limit as the width | variety of the flexible base materials 11 and 21, For example, it is preferable to exist in the range of 50 mm-2000 mm, Preferably it exists in the range of 100 mm-1500 mm.

  In addition, the flexible base materials 11 and 21 may be configured by a single layer, or may be configured by stacking a plurality of layers.

(2) Adhesive layer 30
Next, the material of the adhesive layer 30 will be described. The material of the adhesive layer 30 is not particularly limited as long as it is a flexible material, and is preferably made of an acrylic or styrene resin material. In addition, the thickness of the adhesive layer 30 may be a thickness that does not lose flexibility.

  Next, a method for manufacturing a flexible display device, that is, a method for manufacturing an organic LED display device with a color filter will be described.

  First, the manufacturing process of the carrier-attached color filter (first carrier-attached display portion) 10A will be described with reference to FIGS.

  First, a flexible strip-shaped first carrier 11a and a flexible strip-shaped first substrate 11 are prepared, and then the strip-shaped first carrier 11a and the strip-shaped first substrate 11 are bonded to an adhesive layer (not shown). It joins via the bonding apparatus 50 shown in FIG. 1, and produces flexible flexible strip-shaped base material 11A with a carrier.

  In this case, the first carrier 11 a has greater heat resistance and larger film thickness than the first base material 11. The first carrier 11a and the first base material 11 have substantially the same bending strength. For example, when polyethylene terephthalate is used as the first substrate 11, polyethylene naphthalate or polyimide having higher heat resistance than polyethylene terephthalate can be used as the first carrier 11a.

  Next, the bonding apparatus 50 which bonds the 1st base material 11 and the 1st carrier 11a is demonstrated using FIG. The bonding apparatus 50 shown in FIG. 1 has the 1st delivery roll 51 which delivers the flexible 1st base material 11, and the 2nd delivery roll 52 which delivers the 1st carrier 11a provided with the adhesion layer.

  A laminating unit that laminates the first base 11 fed from the first feeding roll 51 and the first carrier 11 a fed from the second feeding roll 52 on the downstream side of the first feeding roll 51 and the second feeding roll 52. 53 is provided. In the laminating portion 53, the first base material 11 and the first carrier 11a are bonded together via an adhesive layer, and a flexible strip-shaped base material 11A with a carrier is produced. The laminating section 53 includes a pair of pressing rollers 53a and 53b, and a gap L between the pair of pressing rollers 53a and 53b (hereinafter also referred to as “laminate gap”), that is, a gap L between the pressing rollers 53a and 53b. By adjusting the laminating pressure, the laminating pressure when laminating the first base material 11 and the first carrier 11a can be adjusted. Further, the material of the pair of pressing rollers 53a and 53b may be both metal or both may be rubber, or one may be metal and the other may be rubber. Preferably, the pressing roller 53a on the first substrate 11 side is made of metal, The pressing roller 53b on the one carrier 11a side is preferably made of rubber.

  On the downstream side of the laminating portion 53, a winding roll 54 for winding the flexible strip-shaped first carrier-equipped substrate 11A into a roll shape is provided. This winding roll 54 has a function as a drive part which conveys 11 A of flexible base materials with a carrier.

  Moreover, in the bonding apparatus 50 shown in FIG. 1, the torque of the direction opposite to a conveyance direction is loaded to the 1st delivery roll 51 and the 2nd delivery roll 52, and it is conveyed by adjusting this torque. The tension applied to the first base material 11 and the first carrier 11a can be adjusted.

  Next, as shown in FIG. 3, the black matrix 16, the R colored layer 15R, the G colored layer 15G, and the B colored layer 15B are formed on the first substrate 11 of the flexible strip-shaped first carrier-equipped substrate 11A. Sequentially formed using photolithography technology. In this manner, the colored layer (first display portion) 15 including the black matrix 16, the R colored layer 15R, the G colored layer 15G, and the B colored layer 15B is formed on the first base material 11. In this way, a flexible belt-like color filter with carrier (display portion with first carrier) 10A having the first carrier-equipped substrate 11A and the colored layer 15 can be produced.

  Next, a manufacturing process of the organic LED element with a carrier (second display part with a carrier) 20A will be described with reference to FIGS.

  First, a flexible belt-like second carrier 21a and a flexible belt-like second base material 21 are prepared, and then the belt-like second carrier 21a and the belt-like second base material 21 are provided with an adhesive layer (not shown). It joins through the bonding apparatus 60 shown in FIG. 4, and produces the flexible base material 21A with a 2nd carrier.

  In this case, the second carrier 21 a has greater heat resistance and larger film thickness than the second base material 21. The second carrier 21a and the second substrate 21 have substantially the same bending strength. For example, when polyethylene terephthalate is used as the second substrate 21, polyethylene naphthalate or polyimide having higher heat resistance than polyethylene terephthalate can be used as the second carrier 21a.

  Next, the bonding apparatus 50 which bonds the 1st base material 11 and the 1st carrier 11a is demonstrated using FIG. The bonding apparatus 60 shown in FIG. 4 has the 1st delivery roll 61 which delivers the flexible 2nd base material 21, and the 2nd delivery roll 62 which delivers the 2nd carrier 21a provided with the adhesion layer.

  A laminating unit that laminates the second base material 21 fed from the first feeding roll 61 and the second carrier 21 a fed from the second feeding roll 62 on the downstream side of the first feeding roll 61 and the second feeding roll 62. 63 is provided. In the laminate portion 63, the second base material 21 and the second carrier 21a are bonded together via an adhesive layer, and a flexible strip-shaped base material 21A with a carrier is produced. The laminating section 63 includes a pair of pressing rollers 63a and 63b, and a gap L between the pair of pressing rollers 63a and 63b (hereinafter also referred to as “laminate gap”), that is, a gap L between the pressing rollers 63a and 63b. By adjusting the laminating pressure, the laminating pressure when laminating the second base material 21 and the second carrier 21a can be adjusted. Further, the material of the pair of pressing rollers 63a and 63b may be both metal or both may be rubber, or one may be metal and the other may be rubber. Preferably, the pressing roller 63a on the second substrate 21 side is made of metal, The pressure roller 63b on the two carrier 21a side is preferably made of rubber.

  A winding roll 64 is provided on the downstream side of the laminating section 63 to wind up the flexible band-shaped base material 21A with the second carrier in a roll shape. This winding roll 64 has a function as a drive part which conveys flexible 21 A of base materials with a carrier.

  Moreover, in the bonding apparatus 60 shown in FIG. 4, it is conveyed by applying the torque of the opposite direction to a conveyance direction to the 1st delivery roll 61 and the 2nd delivery roll 62, and adjusting this torque. The tension applied to the second base material 21 and the second carrier 21a can be adjusted.

  Next, as shown in FIG. 6, the wiring 28 and the insulating layer 27 are formed on the second base material 21 of the flexible strip-shaped base material 21 </ b> A with the second carrier, and then the partition wall 29 is formed on the wiring 28 and the insulating layer 27. In addition, the reflective electrode 23, the light emitting layer 24, and the transparent electrode 25 are sequentially formed between the partition walls 29 to provide the organic LED layer (second display unit) 22.

  Next, a protective layer 26 is provided on the organic LED layer 22, whereby a flexible strip having the second carrier-equipped substrate 21 </ b> A, the wiring 28 and the insulating layer 27, the organic LED layer 22, and the protective layer 26. 20A of organic LED elements with a carrier (display part with a second carrier) can be produced.

  Next, as shown in FIGS. 7 to 9, the flexible first display portion with carrier 10A and the flexible second display portion with carrier 20A produced as described above are the first display portion with first carrier 10A. The carrier 11 a and the second carrier 21 a of the second carrier-equipped display unit 20 </ b> A are arranged so as to face the outside, and are bonded by the bonding device 70 via the adhesive layer 30.

  Thus, a display device with a carrier (organic LED with a color filter including a carrier) having the first display portion with a carrier (color filter with carrier) 10A and the second display portion with a carrier (organic LED element with carrier) 20A. Element device) 1A is obtained (see FIG. 8).

  Next, the bonding apparatus 70 that bonds the first carrier-equipped display unit 10A and the second carrier-equipped display unit 20A will be described with reference to FIG. The bonding apparatus 70 shown in FIG. 7 has a first feeding roll 71 that feeds out the flexible display unit 10A with a carrier, and a second feeding roll 72 that feeds out the second display unit 20A with a carrier provided with the adhesive layer 30. doing.

  On the downstream side of the first feeding roll 71 and the second feeding roll 72, the first carrier-equipped display unit 10A fed from the first feeding roll 71 and the second carrier-equipped display unit 20A fed from the second feeding roll 72. Is provided. In this laminate portion 73, the first carrier-equipped display portion 10A and the second carrier-equipped display portion 20A are bonded to each other through the adhesive layer 30 to produce a flexible strip-shaped carrier-equipped display device 1A. The laminating unit 73 includes a pair of pressing rollers 73a and 73b, and a gap L between the pair of pressing rollers 73a and 73b (hereinafter also referred to as “laminate gap”), that is, a gap L between the pressing rollers 73a and 73b. Is adjusted so that the laminating pressure when laminating the first carrier-equipped display portion 10A and the second carrier-equipped display portion 20A can be adjusted. Further, the material of the pair of pressing rollers 73a and 73b may be either metal or both may be rubber, or one may be metal and the other may be rubber. Preferably, the pressing roller 73a on the first carrier-equipped display unit 10A side is made of metal. The pressing roller 73b on the second carrier-equipped display portion 20A side is preferably made of rubber.

  On the downstream side of the laminating unit 73, a winding roll 74 for winding the flexible strip-shaped display device 1A with a carrier into a roll is provided. This winding roll 74 has a function as a drive part which conveys flexible display apparatus 1A with a carrier.

  Moreover, in the bonding apparatus 70 shown in FIG. 7, it is conveyed by applying the torque of the opposite direction to a conveyance direction to the 1st delivery roll 71 and the 2nd delivery roll 72, and adjusting this torque. The tension applied to the first carrier-equipped display unit 10A and the second carrier-equipped display unit 20A can be adjusted.

  Next, as shown in FIG. 9, the first carrier 11a of the first carrier-equipped display unit 10A and the second carrier 21a of the second carrier-equipped display unit 20A are peeled from the carrier-equipped display device 1A.

  Thus, the flexible display apparatus (organic LED display apparatus with a color filter) 1 which has the color filter 10, the organic LED element 20, and the contact bonding layer 30 which adhere | attaches these color filter 10 and an organic LED element is obtained. It is done. Thereafter, the strip-shaped display device is cut into individual pieces for each display device.

  Thus, according to the present embodiment, the first carrier-equipped display unit 10A having the first carrier 11a having a large heat resistance and a large film thickness, and the second carrier 21a having a large heat resistance and a large film thickness are provided. The display unit with carrier 1A is manufactured by bonding the second display unit with carrier 20A to each other, and then the first carrier 11a and the second carrier 21a are peeled from the display device with carrier 1A. The dimensional accuracy does not decrease between the first carrier-equipped display portion 10A and the second carrier-equipped display portion 20A when the second carrier-equipped display portion 20A is joined.

  Note that the flexible display device 1 is manufactured by peeling only one of the first carrier 11a and the second carrier 21a without peeling both the first carrier 11a and the second carrier 21a from the carrier-equipped display device 1A. Can do.

<Modification>
Next, a modification of the present invention will be described with reference to FIGS.

  In the modification shown in FIGS. 10 to 15, the carrier-equipped display device 1 </ b> A manufactured in the above embodiment is prepared, and a third carrier-equipped display unit 40 </ b> A is further provided for the carrier-equipped display device 1 </ b> A. The display device 1B is manufactured, and the flexible display device 1 is manufactured by peeling the carrier 21a and the carrier 41a from the additional display device 1B with carrier.

  In the modification shown in FIGS. 10 to 15, the same parts as those in the embodiment shown in FIGS.

  In this modification, a description will be given by taking a touch panel as an example of the third carrier-equipped display unit 40A.

  First, a manufacturing process of the carrier-attached touch panel (third carrier-attached display unit) 40A will be described with reference to FIGS.

  First, a flexible strip-shaped third carrier 41a and a flexible strip-shaped third substrate 41 are prepared, and then the strip-shaped third carrier 41a and the strip-shaped third substrate 41 are bonded to an adhesive layer (not shown). It joins through the bonding apparatus 80 shown in FIG. 10, and produces the flexible base material 41A with a 3rd carrier.

  In this case, the third carrier 41 a has greater heat resistance and larger film thickness than the third base material 41. The third carrier 41a and the third base material 41 have substantially the same bending strength. For example, when polyethylene terephthalate is used as the third substrate 41, polyethylene naphthalate or polyimide having higher heat resistance than polyethylene terephthalate can be used as the third carrier 41a.

  Next, the bonding apparatus 80 which bonds the 3rd base material 41 and the 3rd carrier 41a is demonstrated using FIG. The bonding apparatus 80 shown in FIG. 10 has the 1st delivery roll 81 which delivers the flexible 3rd base material 41, and the 2nd delivery roll 82 which delivers the 3rd carrier 41a provided with the adhesion layer.

  A laminating unit that laminates the third base material 41 fed from the first feeding roll 81 and the third carrier 41 a fed from the second feeding roll 82 on the downstream side of the first feeding roll 81 and the second feeding roll 82. 83 is provided. In the laminating portion 83, the third base material 41 and the third carrier 41a are bonded together via an adhesive layer, and a flexible strip-shaped base material 41A with a carrier is produced. The laminating portion 83 includes a pair of pressing rollers 83a and 83b, and a gap L between the pair of pressing rollers 83a and 83b (hereinafter also referred to as “laminate gap”), that is, a gap L between the pressing rollers 83a and 83b. By adjusting this, the laminating pressure when laminating the third base material 41 and the third carrier 41a can be adjusted. The material of the pair of pressing rollers 83a and 83b may be both metal or both rubber, or one may be metal and the other may be rubber. Preferably, the pressing roller 83a on the third substrate 41 side is made of metal, The pressing roller 83b on the 3 carrier 41a side is preferably made of rubber.

  On the downstream side of the laminating portion 83, a winding roll 84 is provided for winding the flexible belt-like base material 41A with the third carrier 41A into a roll shape. The take-up roll 84 has a function as a drive unit that transports the flexible third substrate with carrier 41A.

  Moreover, in the bonding apparatus 80 shown in FIG. 10, the torque of the direction opposite to a conveyance direction is loaded to the 1st delivery roll 81 and the 2nd delivery roll 82, and it is conveyed by adjusting this torque. The tension applied to the third base material 41 and the third carrier 41a can be adjusted.

  Next, as shown in FIG. 12, a touch panel (third display portion) 42 is formed on the third base material 41 of the base material 11A with the flexible belt-like third carrier, and thus with the flexible belt-like carrier. A touch panel (display unit with a third carrier) 40A is produced.

  On the other hand, as shown in FIGS. 13 to 14, the carrier-equipped display device 1 </ b> A manufactured according to the above-described embodiment is prepared, and the first carrier 31 a of the first carrier-equipped display unit 10 </ b> A is prepared from the carrier-equipped display device 1 </ b> A. It is peeled off.

  Next, the third carrier-equipped display portion 40 </ b> A is bonded via the adhesive 45 on the first base material 11 of the carrier-equipped display device 1 </ b> A. In this way, an additional display device with carrier 1B having the display device with carrier 1A and the third display portion with carrier 40A is obtained.

  Next, the second carrier 21a and the third carrier 41a are peeled from the additional carrier-equipped display device 1B.

  Thereby, the organic LED display device 1 with a color filter having a touch panel can be obtained.

  Next, the bonding apparatus 90 which bonds 1 A of display apparatuses with a carrier and 3rd display part 40A with a carrier is demonstrated using FIG. The bonding apparatus 90 shown in FIG. 13 has a first feeding roll 91 for feeding out the flexible display device 1A with a carrier and a second feeding roll 92 for feeding out the third carrier-equipped display portion 40A provided with the adhesive 45. doing.

  On the downstream side of the first feeding roll 91 and the second feeding roll 92, the carrier-equipped display device 1A fed from the first feeding roll 91 and the third carrier-equipped display unit 40A fed from the second feeding roll 92 are laminated. A laminating portion 93 is provided. In the laminating portion 93, the carrier-equipped display device 1A and the third carrier-equipped display portion 40A are bonded together with an adhesive 45 to produce a flexible additional carrier-equipped display device 1B. The laminating portion 93 includes a pair of pressing rollers 93a and 93b, and a gap L between the pair of pressing rollers 93a and 93b (hereinafter also referred to as “laminate gap”), that is, a gap L between the pressing rollers 93a and 93b. Is adjusted so that the laminating pressure when laminating the display device with carrier 1A and the third display portion with carrier 40A can be adjusted. Further, the material of the pair of pressing rollers 93a and 93b may be both metal or both rubber, or one may be metal and the other may be rubber. Preferably, the pressing roller 93a on the display device with carrier 1A side is made of metal, The pressing roller 93b on the three carrier display portion 40A side is preferably made of rubber.

  On the downstream side of the laminating section 93, a winding roll 94 is provided for winding the flexible strip-shaped additional display device 1B with a carrier into a roll shape. This winding roll 94 has a function as a drive part which conveys flexible additional display equipment 1B with a carrier.

  Moreover, in the bonding apparatus 90 shown in FIG. 13, it is conveyed by applying the torque of the opposite direction to a conveyance direction to the 1st delivery roll 91 and the 2nd delivery roll 92, and adjusting this torque. The tension applied to the carrier-equipped display device 1A and the third carrier-equipped display unit 40A can be adjusted.

  In each of the above embodiments and modifications, the carrier-equipped display device 1A includes the first carrier-equipped display portion 10A and the second carrier-equipped display portion 20A, and the additional carrier-equipped display device 1B is the first carrier. Although the example which has the display part 10A with a display, the display part 20A with a 2nd carrier, and the display part 40A with a 3rd carrier was shown, not only this but the additional display apparatus 1B with a carrier is a display part with a 4th carrier. You may have.

Examples of the display unit with the first carrier, the display unit with the second carrier, the display unit with the third carrier, and the display unit with the fourth carrier are shown below. In the following table, the first-stage display device has a four-layer structure of a color filter, an organic LED, a touch panel, and a liquid crystal lens. The second-stage display device has a three-layer structure of an organic LED, a touch panel, and a liquid crystal lens. The third-stage display device has a four-layer structure of electronic paper, a touch panel, and a liquid crystal lens. Furthermore, the fourth-stage display device has a three-layer structure of electronic paper, a touch panel, and a liquid crystal lens.

1 Organic LED Display Device with Color Filter 1A Display Device with Carrier 1B Additional Display Device with Carrier 10A First Display Unit with Carrier 11 First Base Material 11a First Carrier 11A First Base Material with Carrier 15 Colored Layer 15R Layer 15G G colored layer 15B B colored layer 16 Black matrix 20A Display unit with second carrier 21 Second base material 21a Second carrier 21A Base material with second carrier 22 Organic LED layer 23 Reflective electrode 24 Light emitting layer 25 Transparent electrode 30 Adhesive Layer 40A Display Unit 41 with Third Carrier Third Base Material 41a Third Carrier 41A Base Material with Third Carrier 45 Adhesive

Claims (4)

In a method for manufacturing a flexible display device,
Bonding the belt-shaped first carrier and the belt-shaped first base material to produce a belt-shaped first carrier-attached base material;
Providing a first display part on the first carrier-attached base material to produce a strip-shaped first carrier-attached display part;
Joining the belt-like second carrier and the belt-like second base material to produce the belt-like base material with the second carrier;
Providing a second display portion on the base material with the second carrier to produce a strip-shaped second display portion with a carrier;
Bonding the first base material with carrier and the second base material with carrier so that the first carrier and the second carrier face outward, and producing a display device with carrier;
Separating at least one of the first carrier and the second carrier from the display device with a carrier to obtain a flexible display device,
The first carrier has greater heat resistance than the first substrate,
The second carrier have a greater heat resistance than said second substrate,
The display unit with the first carrier and the display unit with the second carrier are a combination of a color filter and an organic LED, a combination of an organic LED and a touch panel, a combination of a color filter and electronic paper, or a combination of electronic paper and a touch panel.
A method for manufacturing a flexible display device. The first carrier has a larger film thickness than the first substrate;
The method for manufacturing a flexible display device according to claim 1, wherein the second carrier has a larger film thickness than the second base material. In a method for manufacturing a flexible display device,
Bonding the belt-shaped first carrier and the belt-shaped first base material to produce a belt-shaped first carrier-attached base material;
Providing a first display part on the first carrier-attached base material to produce a strip-shaped first carrier-attached display part;
Joining the belt-like second carrier and the belt-like second base material to produce the belt-like base material with the second carrier;
Providing a second display portion on the base material with the second carrier to produce a strip-shaped second display portion with a carrier;
A step of joining the belt-like third carrier and the belt-like third base material to produce a belt-like third carrier-attached base material;
Providing a third display on the third carrier-attached base material to produce a strip-shaped third carrier-attached display;
Joining the first carrier-attached base material and the second carrier-attached base material so that the first carrier and the second carrier face outward, and creating a display device with a carrier;
A display device with an additional carrier is formed by peeling the first carrier from the display portion with the first carrier and joining the display portion with a third carrier on the first display portion so that the third carrier faces outward. A manufacturing process;
Separating at least one of the second carrier and the third carrier from the display device with an additional carrier to obtain a flexible display device,
The first carrier has greater heat resistance than the first substrate,
The second carrier has higher heat resistance than the second substrate,
The third carrier have a greater heat resistance than the third substrate,
The first display unit with a carrier, the second display unit with a carrier, and the third display unit with a carrier are a combination of a color filter, an organic LED, and a touch panel, a combination of an organic LED, a touch panel, and a liquid crystal lens, a color filter, Composed of a combination of electronic paper and touch panel, or a combination of electronic paper, touch panel and liquid crystal lens,
A method for manufacturing a flexible display device. Wherein the first carrier has a large thickness than the first substrate,
The second carrier has a large thickness than the second substrate,
The third carrier manufacturing method of a flexible display device according to claim 3, characterized in that it has a greater thickness than the third substrate.

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