WO2016011712A1 - 柔性显示面板的制造方法和柔性显示装置 - Google Patents

柔性显示面板的制造方法和柔性显示装置 Download PDF

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Publication number
WO2016011712A1
WO2016011712A1 PCT/CN2014/088814 CN2014088814W WO2016011712A1 WO 2016011712 A1 WO2016011712 A1 WO 2016011712A1 CN 2014088814 W CN2014088814 W CN 2014088814W WO 2016011712 A1 WO2016011712 A1 WO 2016011712A1
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Prior art keywords
flexible display
manufacturing
carrier
curable material
display device
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PCT/CN2014/088814
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English (en)
French (fr)
Inventor
刘陆
谢明哲
谢春燕
孙韬
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京东方科技集团股份有限公司
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Priority to US14/769,332 priority Critical patent/US9634270B2/en
Publication of WO2016011712A1 publication Critical patent/WO2016011712A1/zh

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    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
    • H10K59/10—OLED displays
    • H10K59/12—Active-matrix OLED [AMOLED] displays
    • H10K59/1201—Manufacture or treatment
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K77/00—Constructional details of devices covered by this subclass and not covered by groups H10K10/80, H10K30/80, H10K50/80 or H10K59/80
    • H10K77/10—Substrates, e.g. flexible substrates
    • H10K77/111—Flexible substrates
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
    • H10K71/80—Manufacture or treatment specially adapted for the organic devices covered by this subclass using temporary substrates
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00—Organic light-emitting devices
    • H10K50/80—Constructional details
    • H10K50/84—Passivation; Containers; Encapsulations
    • H10K50/844—Encapsulations
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
    • H10K59/10—OLED displays
    • H10K59/12—Active-matrix OLED [AMOLED] displays
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
    • H10K59/80—Constructional details
    • H10K59/87—Passivation; Containers; Encapsulations
    • H10K59/873—Encapsulations
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
    • H10K71/10—Deposition of organic active material
    • H10K71/12—Deposition of organic active material using liquid deposition, e.g. spin coating
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K2102/00—Constructional details relating to the organic devices covered by this subclass
    • H10K2102/301—Details of OLEDs
    • H10K2102/311—Flexible OLED
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/549—Organic PV cells

Definitions

  • Embodiments of the present invention relate to a method of manufacturing a flexible display panel and a flexible display device.
  • OLED Organic Light Emitting Display
  • OLED devices are very sensitive to water vapor and oxygen, and are easily attenuated.
  • the effective packaging prevents moisture and oxygen from immersing, prevents aging of organic materials, and prolongs the life of OLED devices.
  • At least one embodiment of the present invention provides a method for manufacturing a protective film for a flexible display device and a flexible display device, which can form a protective film layer without using a stamping/applying method, which is simple and easy, and does not need to be vacuum-removed subsequently. Bubble process.
  • At least one embodiment of the present invention provides a method for manufacturing a protective film for a flexible display device, comprising: sequentially forming a stack of a substrate, a flexible display device, and a protective layer on a carrier; and flipping the side of the carrier Laying upward with the laminate of the substrate, the flexible display device and the protective layer facing downward; peeling off the carrier; coating the surface of the substrate, the flexible display device and the protective layer after peeling the carrier
  • the curable material is coated; a curing treatment is performed to cure the coated curable material to form a protective film.
  • the curable material is a photocurable material and the curing process corresponds to performing illumination.
  • the photocurable material is, for example, an unsaturated polyester resin.
  • the curable material is a thermosetting material
  • the curing treatment corresponds to performing a heat treatment
  • a coating thickness of the curable material is set as follows: the curable material is cured The post-formed protective film ensures that the flexible display device is on the neutral layer of the entire flexible display panel.
  • the curable material is applied directly to the surface exposed after stripping the carrier in situ.
  • the flexible display panel is adsorbed using a vacuum suction arm, for example, during the manufacturing process.
  • the coating method employed includes spin coating or slot die coating.
  • the carrier is stripped, for example, using a laser lift-off technique.
  • the substrate may be prepared from polyimide, polyethylene naphthalate, polyester, polycarbonate, polyether sulfone or polymethyl methacrylate or the like.
  • At least one embodiment of the present invention also provides a flexible display device comprising the flexible display panel manufactured by the manufacturing method of any one of the above.
  • FIG. 1 is a schematic view of a glass substrate peeled off by a laser lift-off technique
  • FIG. 2 is a flow chart of a method for manufacturing a flexible display panel according to an embodiment of the present invention
  • FIG. 3 is a schematic view showing a method of peeling off a glass substrate by using a laser lift-off technique according to an embodiment of the present invention
  • FIG. 4 is a schematic structural view of a method of coating a curable material in an embodiment of the present invention.
  • FIG. 5 is a schematic structural view of a flexible display panel formed in an embodiment of the present invention.
  • a polyimide (PI) substrate 11 a flexible display device 12 (eg, an OLED device), and a polyimide device (eg, an OLED device) are sequentially formed on a carrier 10 (eg, a glass substrate).
  • a carrier 10 eg, a glass substrate.
  • the protective layer 15 is then turned over so that the carrier 10 is placed upward, and accordingly, the polyimide substrate 11, the flexible display device 12 (for example, an OLED device), and the protective layer 15 are laminated downward, by laser lift-off technology (Laser Lift- Off, LLO) stripping the carrier 10; finally transferring the laminate to a laminator, and laminating the surface of the laminate exposed after the release of the carrier 10 (such as a glass substrate) with a laminator a protective film layer, which is usually made of PEN (polyethylene naphthalate) film or PET (polyethylene terephthalate, for example, high temperature resistant polyester) film, and the film thickness is 125um.
  • PEN polyethylene naphthalate
  • PET polyethylene terephthalate, for example, high temperature resistant polyester
  • the inventors have found that the method of pressing is not only easy to damage the flexible device, but also has the following problems: First, after the glass substrate is peeled off, the flexible display device is soft and not easy to operate, which is disadvantageous for accessing And the transmission; the second is that bubbles are easily generated during the pressing process, so the subsequent vacuum defoaming process is required.
  • the manufacturing method and the flexible display device of the flexible display panel provided by at least one embodiment of the present invention are simple and easy to operate, and there is no air bubble, so that the vacuum defoaming process is not required subsequently.
  • At least one embodiment of the present invention provides a method of manufacturing a flexible display panel. As shown in FIG. 2, the manufacturing method includes:
  • a laminate of a polyimide substrate 11, a flexible display device 12, and a protective layer 15 is sequentially formed on the carrier 10. Since the flexible display panel is soft, it is not easy to operate, and the flexible display panel can be first formed on the carrier 10, and the carrier 10 can be peeled off later.
  • a glass substrate can be used as the carrier.
  • the flexible display device is, for example, an organic light emitting display, an electronic paper display, or the like, and the preparation method, structure, and the like can be implemented by known techniques, and the present invention is not limited to the selection of the flexible display device.
  • the carrier 10 on which the above laminate is formed is turned over such that the side on which the carrier 10 is placed faces upward as shown in FIG.
  • the carrier 10 of the step 101 is flipped so that the side of the flexible display device 12 and the protective layer 15 is facing downward, and the side of the carrier 10 is facing upward, thereby exposing the carrier 10 to facilitate the lowering.
  • the step of peeling off the carrier 10 is performed in one step.
  • the carrier 10 is peeled off from the flexible display panel, and the specific means is not limited. If a glass substrate is used as the carrier, the carrier 10 can be peeled off by Laser Lift-off (LLO).
  • LLO Laser Lift-off
  • the conversion of a substance from a liquid to a solid is collectively referred to as the curing process.
  • the curable material is applied to the manufacture of the protective film of the flexible display device, the curable material that meets the requirements of the protective film after film formation is selected, the film is formed, and then the suitable conditions are selected to promote the curing reaction to occur, so that the curable material is made. Curing forms a protective film.
  • the curable material for forming the protective film in this step is not limited to a single material as long as it contains a component capable of undergoing a curing reaction.
  • Practical coating methods for this step include: spin-coat or slot-die coating. These two methods can be used for materials with different viscosities. If the viscosity of the material is less than 1000 cp, spin coating is applied, and if the viscosity of the material is from 1000 to 10,000, the method of slot die coating is employed. Other film forming methods, such as filming, can cause damage to the flexible device caused by pressure during the coating process, and coating film formation can avoid such damage to the flexible device, and the thickness of the film layer can be adjusted.
  • the film-formable curable material 13 is placed under suitable conditions to cause a curing reaction to occur, and the curable material 13 is cured to form the protective film 14.
  • the substrate is not limited to the polyimide substrate 11, and other materials such as polyethylene naphthalate (PEN) and polyester (PET) which can be used for a flexible display device of a flexible display device can also be used. ), polycarbonate (PC), polyether sulfone (PES), polymethyl methacrylate (PMMA), and the like.
  • PEN polyethylene naphthalate
  • PET polyester
  • PC polycarbonate
  • PES polyether sulfone
  • PMMA polymethyl methacrylate
  • the flexible display is first fabricated on a carrier, and then the carrier is peeled off and cured on the exposed surface after the carrier is peeled off.
  • the film is formed in a manner of a film. This operation is simple and easy, and it is not necessary to transfer to the pressing/adhesive device to press/adhere the film, and the formed protective film has no bubbles, and the subsequent vacuum defoaming process is not necessary.
  • the film forming method employed in at least one embodiment of the present invention can be applied in situ to form a film without positional shifting.
  • the protective film formed as described above can be adjusted in thickness of the film layer so that the flexible display device is placed on the neutral layer of the entire display device, so that the flexible display device does not easily fall off from the electrode when bent.
  • the flexible display device is in the neutral layer of the entire display device
  • the thickness of the laminate of the various film layers on the upper and lower sides of the flexible display device is made equal, so that the film layer on the flexible display device is subjected to the bending process.
  • the underlying film layer is squeezed, and the flexible display device is in a transition layer that is neither pulled nor pressed, wherein the stress is almost equal to zero, that is, the stress of the "neutral layer” during the bending process is almost zero.
  • the coating thickness of the curable material is selected to be an appropriate value, which can be set as follows:
  • the protective film formed after the curing material is cured can ensure that the flexible display device is on the neutral layer of the entire flexible display panel.
  • the thickness of the protective film required for the flexible display device to be on the neutral layer of the entire flexible display panel can be calculated according to the simulation test, and then the step 104 needs to coat the thickness of the curable material.
  • the curable material described in at least one embodiment of the present invention is a photocurable material, and the curing treatment corresponds to performing illumination.
  • Photocuring refers to the curing process of a monomer, oligomer or polymer matrix under light induction and can be used in the film formation process.
  • the photocuring reaction is essentially a photoinitiated polymerization and crosslinking reaction.
  • photocurable materials There are many kinds of photocurable materials and mature technologies.
  • photocurable coatings there are widely used photocurable coatings, photocurable inks and photocurable adhesives.
  • the photocurable material is applied to the manufacture of a protective film of a flexible display device, and the surface of the protective film to be formed is coated and illuminated to form a protective film, which can be directly irradiated in situ without positional shift. It is simple and easy, and the protective film formed has no air bubbles.
  • the protective film formed as described above can be adjusted in thickness of the film layer so that the flexible display device can be placed on the neutral layer of the entire display device.
  • the photocurable material for forming a protective film in at least one embodiment of the present invention the composition of which is not limited to a material which initiates photocuring.
  • the photocurable material in at least one embodiment of the present invention is only required to contain a component capable of producing a photocuring change.
  • the photocurable material may include an unsaturated polyester resin, Epoxy acrylic resin, etc.
  • the curable material according to at least one embodiment of the present invention may also be a heat curing material, and the curing treatment corresponds to performing heat treatment.
  • a thermosetting material is used, and in the curing process, heating can be performed in an oven to cure the material.
  • the heat curing operation is simple and convenient, and the operation can be completed in a simple oven.
  • the curable material and the curing treatment manner do not affect the specific implementation effects of the embodiments of the present invention. Therefore, the curable material used in at least one embodiment of the present invention and the corresponding curing treatment manner thereof are not limited, and Any material and any means of curing that can be conceived by those skilled in the art within the scope of the present disclosure. The following is a detailed description of the photocurable material.
  • a glass substrate is generally used as the carrier 10 in the manufacture of the flexible display device.
  • the carrier 10 ie, the glass
  • the substrate is inverted, and the carrier 10 is peeled off by a laser lift-off technique.
  • the surface of the glass substrate (corresponding to the carrier 10 in the drawing) is coated with a photocurable material ( Corresponding to the curable material 13) in the figure, as shown in FIG. 4; then, the light is applied to cure the coated photocurable material to form a protective film 14, as shown in FIG.
  • the flexible display device is relatively soft after being peeled off from the glass substrate, it is disadvantageous for access and transfer. Therefore, in the second specific example of the embodiment, after the inversion, the vacuum is used.
  • the adsorption arm 20 adsorbs the flexible display device from the lower surface shown in the drawing such that the glass substrate is placed upward, and the flexible display device 12 is located under the glass substrate.
  • the flexible display device 12 (along with the PI substrate 11) does not leave the vacuum adsorption arm 20; and the use of such a coating illumination method eliminates the positional transfer and the pressing step of the protective film, not only avoiding The pressure during the pressing process may cause damage to the flexible display device 12, and the generation of bubbles during the pressing process is also avoided, and the subsequent vacuum defoaming process is not necessary.
  • the above process is simple and easy to form, and it is possible to improve efficiency and yield and reduce cost without positional shift.
  • At least one embodiment of the present invention also provides a flexible display device comprising the flexible display panel formed by the above method.
  • the display device may be: electronic paper, OLED panel, mobile phone, tablet computer, television, display, notebook computer, digital photo frame, navigator, watch, etc. Product or component.
  • the protective film is simple to manufacture, low in cost, high in film formation quality, and free from air bubbles.
  • At least one embodiment of the present invention does not limit the curable material forming the protective film, and may be any curable material that is well known to those skilled in the art to meet the requirements of the protective film.
  • the technical solution described in the embodiments of the present invention relates to an OLED flexible display device and a manufacturing process thereof
  • the application of the technical solution described in the embodiments of the present invention is not limited to the OLED flexible display device, and any protective film package may be expanded. s installation.
  • currently available display technologies for flexible display include LCD (Liquid Crystal Display), EPD (Electro Phoretic Display), PDLC (Polymer Dispersed Liquid Crystal), and CLC (Cholesteric). Phase liquid crystal, cholesteric liquid crystal, etc., these technical flexible display devices and their protective film manufacturing, the technical solutions described in the embodiments of the present invention are equally applicable.
  • the manufacturing method and the flexible display device of the flexible display panel provided by the embodiments of the present invention form a protective film by coating a curable material on the laminate after peeling off the carrier, and then performing a curing treatment to form a protective film by curing the curable material.
  • the laminate is transferred to a crimping/adhesive device.
  • the operation is simple and easy, and there is no air bubble, so there is no need to perform a vacuum defoaming process subsequently; and the protective film formed by the above method can adjust the thickness of the film layer, so that, for example, the flexible display device can be placed in the entire display panel. On the layer, the flexible display panel is not easily peeled off from the electrode when bent.

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  • Manufacturing & Machinery (AREA)
  • Microelectronics & Electronic Packaging (AREA)
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  • Devices For Indicating Variable Information By Combining Individual Elements (AREA)
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Abstract

一种柔性显示面板的制造方法和柔性显示装置，该柔性显示面板的制造方法包括：在载板（10）上依次形成基板（11）、柔性显示器件（12）及保护层（15）；翻转，使载板（10）所在的一面朝上；剥离载板（10）；在剥离载板（10）后的表面上涂覆可固化材料（13）；进行固化处理，使涂覆的可固化材料（13）固化形成保护膜（14）。该柔性显示面板的制造方法无须采用压覆/贴覆方式也能够形成保护膜层，简单易行，且后续也不需要进行真空脱泡工序。

Description

柔性显示面板的制造方法和柔性显示装置 技术领域
本发明的实施例涉及一种柔性显示面板的制造方法和柔性显示装置。
背景技术
传统的平板显示器件技术发展已日趋成熟，柔性显示器件凭借其轻薄、可弯折、耐冲击的特性即将成为显示领域的主流。目前可实现柔性显示的显示技术中，有机发光二极管显示(Organic Light Emitting Display,OLED)因具有响应速度快、视角宽、亮度高、低功耗等优异性能并且为自发光器件，抗弯折等特性，近年来，成为柔性显示领域研究的重点。
OLED器件对水汽、氧气非常敏感，很容易发生衰减，有效的封装可以防止水汽和氧气的浸入，防止有机材料老化，延长OLED器件寿命。
发明内容
本发明的至少一实施例提供一种柔性显示装置保护膜的制造方法和柔性显示装置，无须采用压覆/贴覆方式也可形成保护膜层，简单易行，且后续也不需要进行真空脱泡工序。
本发明至少一实施例提供一种柔性显示装置保护膜的制造方法，包括：先在载板上依次形成基板、柔性显示器件及保护层的叠层；翻转，使所述载板所在的一面朝上而所述基板、柔性显示器件及保护层的叠层朝下；剥离所述载板；在剥离所述载板后的所述基板、柔性显示器件及保护层的叠层的表面上涂覆可固化材料；进行固化处理，使涂覆的所述可固化材料固化形成保护膜。
在一个示例中，例如，所述可固化材料为光固化材料，所述固化处理对应为进行光照。
在一个示例中，所述光固化材料例如为不饱和聚酯树脂。
在一个示例中，例如，所述可固化材料为热固化材料，所述固化处理对应为进行热处理。
在一个示例中，例如，所述在剥离所述载板后的表面上涂覆可固化材料的工序中，所述可固化材料的涂覆厚度按下述要求进行设置：所述可固化材料固化后形成的保护膜，能保证所述柔性显示器件处于整个柔性显示面板的中性层上。
在一个示例中，例如，直接原位在剥离所述载板后露出的表面上涂覆可固化材料。
在一个示例中，例如，在制造过程中，采用真空吸附手臂吸附所述柔性显示面板。
在一个示例中，例如，所述在剥离所述载板后的表面上涂覆可固化材料的工序中，采用的涂覆方式包括：旋转涂布或者槽模涂布。
在一个示例中，例如，采用激光剥离技术剥离所述载板。
在本发明的至少一个实施例中，例如所述基板可以由聚酰亚胺、聚萘二甲酸乙二醇酯、聚酯、聚碳酸酯、聚醚砜或聚甲基丙烯酸甲酯等制备。
本发明至少一实施例还提供一种柔性显示装置，包括任一项所述的制造方法制造出的柔性显示面板。
附图说明
为了更清楚地说明本发明实施例的技术方案，下面将对实施例的附图作简单地介绍，显而易见地，下面描述中的附图仅仅涉及本发明的一些实施例，而非对本发明的限制。
图1为一种采用激光剥离技术剥离玻璃基板的示意图；
图2为本发明实施例提供的柔性显示面板的制造方法流程图；
图3为本发明实施例中采用激光剥离技术剥离玻璃基板的示意图；
图4为本发明实施例中涂覆可固化材料后的结构示意图；
图5为本发明实施例中形成的柔性显示面板的结构示意图。
附图标记
10-载板，11-聚酰亚胺基板，12-柔性显示器件，13-可固化材料，
14-保护膜，15-保护层，20-真空吸附手臂。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例的附图，对本发明实施例的技术方案进行清楚、完整地描述。显然，所描述的实施例是本发明的一部分实施例，而不是全部的实施例。基于所描述的本发明的实施例，本领域普通技术人员在无需创造性劳动的前提下所获得的所有其他实施例，都属于本发明保护的范围。
如图1所示，为制作方便，制作OLED柔性显示装置时，先在载板10(如玻璃基板)上依次形成聚酰亚胺(PI)基板11、柔性显示器件12(例如OLED器件)及保护层15；然后翻转使载板10朝上放置，相应地聚酰亚胺基板11、柔性显示器件12(例如OLED器件)及保护层15的叠层朝下，通过激光剥离技术(Laser Lift-off，LLO)将载板10剥离；最后将上述叠层转移到覆膜机上，在载板10(如玻璃基板)剥离后露出的叠层的表面上用覆膜机压覆粘有背胶的保护膜层，所述保护膜层的材质通常为PEN(聚萘二甲酸乙二醇酯)膜或者PET(聚对苯二甲酸乙二醇酯，例如即耐高温聚酯)膜，膜厚为125um。
对于如图1所示的技术方案，发明人发现，采用压覆的方法不仅容易破坏柔性器件，并且还存在如下问题：一是玻璃基板剥离后，柔性显示器件柔软不好操作，不利于取用和传送；二是在压覆过程中容易产生气泡，因此后续还需进行真空脱泡的工序。
本发明至少一实施例提供的柔性显示面板的制造方法和柔性显示装置，简单易行，而且没有气泡，因此后续也不需要进行真空脱泡工序。
本发明至少一实施例提供一种柔性显示面板的制造方法，如图2所示，该制造方法包括：
101、在载板10上依次形成聚酰亚胺基板11、柔性显示器件12及保护层15；
参照图3所示，本步骤在载板10上依次形成聚酰亚胺基板11、柔性显示器件12及保护层15的叠层。因为柔性显示面板柔软，所以不好对其操作，可先将柔性显示面板制作在载板10上，后期再将载板10进行剥离。具体实施时，可采用玻璃基板作为载板。在本发明的实施例中柔性显示器件例如为有机发光显示器、电子纸显示器等，其制备方法和结构等可以采用已知的技术实现，本发明不限制于柔性显示器件的选择。
102、将形成有上述叠层的载板10翻转，使所述载板10所在的一面朝上，如图3所示。
本步骤对完成步骤101的载板10进行翻转，使柔性显示器件12及保护层15所在的一面朝下，而载板10所在的一面朝上，由此使载板10暴露，便于下一步骤进行剥离载板10的工序。
103、剥离载板10，如图4所示。
本步骤将载板10从柔性显示面板上剥离，具体手段不做限定。如果采用玻璃基板作为载板，可采用激光剥离技术(Laser Lift-off，LLO)将载板10剥离。
104、在剥离所述载板后的表面上涂覆可固化材料13，如图5所示。
物质由液态转变为固态统称为固化过程。本实施例将可固化材料应用于柔性显示装置保护膜的制造，选择成膜后符合保护膜要求的可固化材料，涂覆成膜，然后选择合适条件促使固化反应发生，使所述可固化材料固化形成保护膜。本步骤用以形成保护膜的可固化材料并不限于单一材料，只要包含能发生固化反应的组分即可。
本步骤实用的涂覆方式包括：旋转涂布(spin-coat)或者槽模涂布(slot-die coat)。这两种方式可分别针对不同的粘度的材料。如果材料的粘度小于1000cp，用旋转涂布，如果材料的粘度在1000～10000，则采用槽模涂布的方式。其他成膜方式如贴膜，会在贴覆过程中产生压力对柔性器件造成的损伤，而涂覆成膜可以避免对柔性器件造成的该种损伤，并且膜层的厚度可以调整。
105、进行固化处理，使涂覆的所述可固化材料13固化形成保护膜14，如图5所示。
本步骤将涂覆成膜的可固化材料13置于合适条件下，促使其发生固化反应，使所述可固化材料13固化形成保护膜14。
本发明的实施例中，基板不限于聚酰亚胺基板11，也可以使用其他可用于柔性显示装置的塑料基板的材料制备，例如聚萘二甲酸乙二醇酯(PEN)、聚酯(PET)、聚碳酸酯(PC)、聚醚砜(PES)、聚甲基丙烯酸甲酯(PMMA)等。
本发明至少一实施例所述柔性显示面板的制造方法，先在载板上完成柔性显示的制造，然后将载板剥离，并在载板剥离后露出的表面上利用固化成 膜的方式形成保护膜。该操作简单易行，无需转移到压覆/贴覆设备上压覆/贴覆薄膜，而且形成的保护膜没有气泡，后续也不必进行真空脱泡的工序。虽然剥离载板后的柔性显示面板柔软不易操作，但是本发明至少一实施例中采用的成膜方法，可以在原位进行涂覆成膜，不必进行位置转移。按上述方法形成的保护膜，其膜层的厚度可以调整，这样可以使得柔性显示器件处于整个显示器件的中性层上，使得柔性显示器件在弯折的时候不容易与电极脱落。
本公开中“柔性显示器件处于整个显示器件的中性层”的意思是指，让柔性显示器件上下各种膜层的叠层的厚度相等，这样在弯曲过程中，柔性显示器件上方膜层受拉伸，下方膜层受挤压，柔性显示器件处于既不受拉，又不受压的过渡层，其中应力几乎等于零，即“中性层”在弯曲过程中其中的应力几乎为零。这就要求步骤104在剥离所述载板后的表面上涂覆可固化材料的工序中，所述可固化材料的涂覆厚度要选择合适的数值，可按下述要求进行设置：所述可固化材料固化后形成的保护膜，能保证柔性显示器件处于整个柔性显示面板的中性层上。具体实施时，可以通过根据模拟试验，计算出柔性显示器件处于整个柔性显示面板的中性层上需要的所述保护膜的厚度，然后反推步骤104需要涂覆可固化材料的厚度。
例如，本发明至少一实施例中所述的可固化材料为光固化材料，所述固化处理对应为进行光照。
光固化指单体、低聚体或聚合体基质在光诱导下的固化过程，可用于成膜过程。光固化反应本质上是光引发的聚合、交联反应。光固化材料种类繁多，技术成熟，目前应用广泛的有光固化涂料、光固化油墨和光固化胶粘剂。本发明至少一实施例将光固化材料应用于柔性显示装置保护膜的制造，在待形成保护膜的表面进行涂覆并光照，使之形成保护膜，可以直接在原位进行光照，不必位置转移，简单易行，而且形成的保护膜没有气泡。并且，按上述方法形成的保护膜，其膜层的厚度可以调整，这样可以使得柔性显示器件处于整个显示器件的中性层上。
本发明至少一实施例中用以形成保护膜的光固化材料，其组分不限于引发光固化的材料。本发明至少一实施例中所述光固化材料只要包含能产生光固化变化的组分即可。举例而言，所述光固化材料可以包括不饱和聚酯树脂， 环氧丙烯酸树脂等。
本发明至少一实施例所述可固化材料还可以为热固化材料，所述固化处理则对应为进行热处理。具体而言，采用热固化材料，固化处理时可在烘箱中进行加热，使材料固化。热固化操作简单便捷，使用简单的烘箱即可完成操作。
显而易见地，采用何种可固化材料及固化处理方式并不影响本发明实施例的具体实施效果，因此，本发明至少一实施例采用的可固化材料及其对应的固化处理方式不做限定，可以是本领域技术人员在本发明揭示范围内所能想到的任何材料及任何固化方式。下面以光固化材料为例，进行详细介绍。
如图3所示，为制造方便，通常采用玻璃基板作为柔性显示装置制造中的载板10，完成PI基板11和柔性显示器件12及保护层15的制造后，再将载板10(即玻璃基板)翻转，通过激光剥离技术剥离载板10，本实施例的一种具体的实施方式中，即在剥离玻璃基板(对应图中的载板10)后露出的表面上涂覆光固化材料(对应图中的可固化材料13)，如图4所示；然后进行光照，使涂覆的所述光固化材料固化形成保护膜14，如图5所示。
另外，继续参照图4和图5所示，因玻璃基板剥离后柔性显示器件比较柔软，不利于取用和传送，因此，本实施例的第二种具体示例的方式中，翻转后，采用真空吸附手臂20从图中所示的下表面吸附柔性显示装置，使玻璃基板朝上放置，柔性显示器件12位于玻璃基板的下方，玻璃基板剥离时，重力的作用也容易使柔性显示器件12(连同PI基板11)从玻璃基板上脱落；然后，不做任何移动或位置改变，直接原位在剥离玻璃基板后露出的表面上涂覆光固化材料(对应图中的13)，然后进行光照形成保护膜14。在整个保护膜的制作过程中，柔性显示器件12(连同PI基板11)都不离开真空吸附手臂20；而且使用这种涂覆光照方式，省去位置转移以及保护膜的压覆步骤，不仅避免了压覆过程中压力可能对柔性显示器件12产生损坏的可能，而且还避免了压覆过程中气泡的产生，后续也不必进行真空脱泡的工序。另外，上述工艺成膜简单易行，不必位置转移也可提高效率及良品率，降低成本。
本发明至少一实施例还提供一种柔性显示装置，包括上述方法形成的柔性显示面板。所述显示装置可以为：电子纸、OLED面板、手机、平板电脑、电视机、显示器、笔记本电脑、数码相框、导航仪、手表等任何具有显示功 能的产品或部件。基于上面已描述过的原因，保护膜制造时简单易行，成本低而且成膜质量高，没有气泡。
本发明至少一实施例对形成保护膜的可固化材料不做限定，可以是本领域技术人员所熟知的符合保护膜要求的任意可固化材料。
另外，本发明实施例所述的技术方案虽然涉及OLED柔性显示装置及其制造过程，但本发明实施例所述的技术方案的应用并不限于OLED柔性显示装置，还可扩大任何需要保护膜封装的装置。例如，目前可以实现柔性显示的显示技术中还有LCD(Liquid Crystal Display，液晶显示)、EPD(Electro Phoretic Display，电子纸显示)、PDLC(Polymer Dispersed Liquid Crystal，聚合物分散液晶)、CLC(Cholesteric phase Liquid Crystal，胆甾相液晶)等，这些技术柔性显示装置及其保护膜制造，本发明实施例所述的技术方案同样适用。
本发明实施例提供的柔性显示面板的制造方法和柔性显示装置，在剥离载板后在叠层上涂覆可固化材料，然后进行固化处理使可固化材料固化的方式形成保护膜，无需将上述叠层转移到压覆/贴覆设备上。操作简单易行，而且没有气泡，因此后续也不需要进行真空脱泡工序；并且按上述方法形成的保护膜，其膜层的厚度可以调整，这样例如可以使得柔性显示器件处于整个显示面板的中性层上，使得柔性显示面板在弯折的时候不容易与电极脱落。
本说明书中的各个实施例均采用递进的方式描述，各个实施例之间相同相似的部分互相参见即可，每个实施例重点说明的都是与其他实施例的不同之处。
以上所述仅是本发明的示范性实施方式，而非用于限制本发明的保护范围，本发明的保护范围由所附的权利要求确定。
本申请要求于2014年7月22日递交的中国专利申请第201410350125.7号的优先权，在此全文引用上述中国专利申请公开的内容以作为本申请的一部分。

Claims (11)

  1. 一种柔性显示面板的制造方法，包括：
    在载板上依次形成基板、柔性显示器件及保护层的叠层；
    翻转，使所述载板所在的一面朝上而所述基板、柔性显示器件及保护层的叠层朝下；
    剥离所述载板；
    在剥离所述载板后的所述基板、柔性显示器件及保护层的叠层的表面上涂覆可固化材料；
    进行固化处理，使涂覆的所述可固化材料固化形成保护膜。
  2. 根据权利要求1所述的制造方法，其中，所述可固化材料为光固化材料，所述固化处理对应为进行光照。
  3. 根据权利要求2所述的制造方法，其中，所述光固化材料为不饱和聚酯树脂。
  4. 根据权利要求1所述的制造方法，其中，所述可固化材料为热固化材料，所述固化处理对应为进行热处理。
  5. 根据权利要求1-4任一项所述的制造方法，其中，所述在剥离所述载板后的表面上涂覆可固化材料的工序中，所述可固化材料的涂覆厚度按下述要求进行设置：
    所述可固化材料固化后形成的保护膜，能保证所述柔性显示器件处于整个柔性显示面板的中性层上。
  6. 根据权利要求1-5任一项所述的制造方法，其中，
    直接原位在剥离所述载板后露出的表面上涂覆可固化材料。
  7. 根据权利要求1-6任一项所述的制造方法，其中，在制造过程中，采用真空吸附手臂吸附所述柔性显示面板。
  8. 根据权利要求1-7任一项所述的制造方法，其中，所述在剥离所述载板后的表面上涂覆可固化材料的工序中，采用的涂覆方式包括：旋转涂布或者槽模涂布。
  9. 根据权利要求1-4任一项所述的制造方法，其中，
    采用激光剥离技术剥离所述载板。
  10. 根据权利要求1-9任一项所述的制造方法，其中，所述基板可以由聚酰亚胺、聚萘二甲酸乙二醇酯、聚酯、聚碳酸酯、聚醚砜或聚甲基丙烯酸甲酯制备。
  11. 一种柔性显示装置，包括权利要求1-10任一项所述的制造方法制造出的柔性显示面板。
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