Patent Description:
A micro light-emitting diode (micro-LED) is an ultra-small inorganic light-emitting material that emits light, and might not require a color filter or a backlight to do so. Specifically, the micro-LED may refer to an ultra-small LED having a length that is <NUM>/10th of the length of a general LED chip, and an area that is <NUM>/100th the area of a general LED chip. Further, a micro-LED may have a width, a length, and a height of <NUM> to <NUM> micrometers (µm).

A display screen may be implemented by disposing the micro-LED on a substrate of a display to radiate light in a forward direction. However, the micro-LED may radiate light from its lateral surface as well as from its upper surface to be directed forward, and thus, it may be difficult to use the light of the micro-LED that is radiated from its lateral surface in implementing the display screen. Accordingly, the light efficiency of the micro-LED may decrease, and the power consumption of the display device may increase.

In addition, to the micro-LED and/or the electronic components disposed near the micro-LED may be damaged based on the heat generated from the micro-LED when the micro-LED emits light.

<CIT> describes a display apparatus including a light emitting diode part, including a plurality of regularly arranged light emitting diodes, and a TFT panel part configured to drive the light emitting diode part. <CIT> describes a display device including a lower substrate disposed with a line electrode at an upper portion thereof. <CIT> describes a COB display module comprising a PCB plate, a plurality of LED light-emitting units, an encapsulating rubber layer and light-shielding layers. <CIT> describes light emitting diode devices, method and systems. <CIT> describes a semiconductor light-emitting device, including a wavelength converting layer encapsulating at least one semiconductor light-emitting chip, and a method for manufacturing the same. <CIT> discloses a light emitting module and a display device.

Embodiments of the disclosure may overcome the above disadvantages and other disadvantages not described above. Also, the disclosure is not required to overcome the disadvantages described above, and an embodiment of the disclosure may not overcome any of the problems described above.

There is provided a display module in accordance with claim <NUM> and a method of manufacturing the display module in accordance with claim <NUM>.

The embodiments of <FIG> and <FIG> are embodiments in accordance with the invention as claimed. The other figures represent illustrative examples showing some but not all features of the invention claimed.

In order to fully understand the constitutions and effects of the disclosure, the embodiments of the disclosure will be described with reference to the accompanying drawings. However, the disclosure is not limited to the embodiments which will be described below, and may be implemented in various forms according to various modifications. The embodiments disclosed herein are provided for those skilled in the art to understand the disclosure and the scope of the claims. In the accompanying drawings, elements may be exaggerated in size for convenience of explanation, and the proportions of the elements may be exaggerated or reduced.

It should be understood that when an element is referred to as being "on" or "in contact with" another element, the element may be in contact with or connected to the another element in a direct manner or via an intervening element. It should be understood that when an element is referred to as being "directly on" or "directly in contact with" another element, there may be no intervening elements. Other expressions for explaining the relationship among elements, for example, "between" and "directly between" may be interpreted similarly.

It should be understood that although the terms "first," "second," and the like, may be used herein to describe various elements, these elements should not be limited by these terms. These terms may be used to distinguish one element from another element. For example, the "first" element may be referred to as the "second" element, and similarly, the "second" element may also be referred to as the "first" element, without departing from the scope of the claims.

Singular forms of terms may include the plural forms of the terms unless the context clearly indicates otherwise. Terms such as "include," "have," and the like, may be used to indicate the presence of features, numerals, steps, operations, components, parts, or combinations thereof, mentioned in the specification, but it should also be understood that one or more other features, numerals, steps, operations, components, parts, or combinations thereof may be added.

The terms used to describe the embodiments of the disclosure may be construed based on their meanings as known to those skilled in the art unless otherwise defined.

Hereinafter, the structure of a display apparatus <NUM> according to the disclosure will be described with reference to <FIG>.

<FIG> is an exploded perspective view illustrating a display apparatus <NUM> according to an embodiment of the disclosure.

The display apparatus <NUM> may be a device configured to process an image signal received from an external source and visually display the processed image, and may be implemented in various forms, such as a television, a monitor, a portable multimedia device, a portable communication device, and the like.

A protective plate <NUM> may be disposed on a front surface (in a Y-axis direction) of the display apparatus <NUM>, and may protect a plurality of display modules <NUM> disposed behind the protective plate <NUM> from external disturbances.

The protective plate <NUM> may be comprised of a glass material having a thin thickness, or comprised of any various materials.

The plurality of display modules <NUM> may be configured to display an image in a forward direction (in the Y-axis direction) based on an image signal received from an external source.

In addition, the plurality of display modules <NUM> may implement a display screen. For example, each display module <NUM> may be manufactured based on a size of the display to be implemented, and may be arranged to implement the display screen.

For example, when first and second display modules <NUM> and <NUM> are arranged in a side by side manner in a transverse direction (X-axis direction), the display screen may be implemented to be longer in the transverse direction (X-axis direction) than in a longitudinal direction (Z-axis direction).

In addition, when the first and third display modules <NUM> and <NUM> are arranged in a side by side manner in the longitudinal direction (Z-axis direction), the display screen may be implemented to be longer in the longitudinal direction (Z-axis direction) than the transverse direction (X-axis direction).

Therefore, the display screen may be implemented in various sizes and forms based on the number and the form of a plurality of display modules <NUM> arranged to form the display screen.

The display module <NUM> will be described in more detail elsewhere herein with reference to <FIG>.

An array plate <NUM> may be a plate on which the plurality of display modules <NUM> may be disposed, and is disposed on rear surfaces of the plurality of display modules <NUM>. The array plate <NUM> may be formed as a flat plate, and may be formed in various forms and sizes based on the form and size of the plurality of display modules <NUM>.

Accordingly, the array plate <NUM> may support the plurality of display modules <NUM> such that the plurality of display modules <NUM> are disposed in parallel with each other on the same plane, and implement the same height between the display modules <NUM> and the uniform luminance of the display screen.

A housing <NUM> may form an appearance of the display apparatus <NUM>, may be disposed behind the array plate <NUM>, and may stably fix the plurality of display modules <NUM> and the array plate <NUM>.

In addition, the housing <NUM> may stably fix an edge region of the protective plate <NUM>.

Accordingly, the housing <NUM> may prevent various components included in the display apparatus <NUM> from being externally exposed, and protect the various components included in the display apparatus <NUM> from external impacts.

Hereinafter, the specific structure and operation of the display module <NUM> will be described with reference to <FIG>.

The display module <NUM> according to an embodiment of the disclosure may be applied to an electronic product or an electronic device that implements a wearable device, a portable device, a handheld device, or various displays, in a single unit. The display module may also be applied to a small display device such as a monitor for a personal computer, a TV, etc., and a large display device such as a digital sign, an electronic display including a plurality of assembly arrangements, and the like.

<FIG> is a top view illustrating a display module <NUM> according to an embodiment of the disclosure, and <FIG> is a block diagram illustrating an operation of the display module <NUM>.

Here, the display modules <NUM> are included in plural, but the following description will be based on a single display module <NUM> for convenience of explanation.

The first display module <NUM> may include micro light-emitting diodes (micro-LEDs) <NUM>, a substrate <NUM> on which the micro-LEDs <NUM> are disposed in a lattice form, and a driver <NUM> driving each of the micro-LEDs <NUM>.

The micro-LEDs <NUM> may be comprised of an inorganic light-emitting material having a size of less than or equal to <NUM> micrometer (µm)in width, length, and height, respectively, may be disposed on the substrate <NUM>, and may be configured to radiate light.

The micro-LEDs <NUM> may include a first micro-LED <NUM> configured to emit red light, a second micro-LED <NUM> configured to emit green light, and a third micro-LED <NUM> configured to emit blue light.

The first to third micro-LEDs <NUM>, <NUM>, and <NUM> may be sequentially disposed on the substrate <NUM>.

Accordingly, the first to third micro-LEDs <NUM>, <NUM>, and <NUM> may form a single pixel and may implement various colors.

As shown in <FIG>, the first to third micro-LEDs <NUM>, <NUM>, and <NUM>, which are sub-pixels, may be sequentially disposed on the substrate <NUM>, however the first to third micro-LEDs <NUM>, <NUM>, and <NUM> may also be formed as a single pixel.

Even if the first to third micro-LEDs <NUM>, <NUM>, and <NUM> form a single pixel, the structures of a reflective layer <NUM> and a light blocking layer <NUM>, which will be described in more detail elsewhere herein, may be the same.

The micro-LED <NUM> has been described as a light-emitting device of a next generation display because of its fast response speed, low power consumption, and high luminance. Specifically, the micro-LED <NUM> is more efficient in converting electricity into photons than conventional liquid crystal displays (LCDs) or organic light emitting diodes (OLEDs).

That is, the micro-LED <NUM> has a higher "brightness per watt" than the conventional LCD or OLED displays. As a result, the micro-LED <NUM> consumes substantially half of the energy required by the conventional LED or OLED displays to produce the same brightness.

Furthermore, the micro-LED <NUM> may implement a high resolution, an excellent color, a high contrast, and a high brightness, thereby accurately expressing a wide range of colors and also implementing a clear screen even in bright sunlight in outdoor environments. In addition, the micro-LED <NUM> is resistant to burn-in phenomena and generates less heat, thereby providing improved product lifespan without deformation.

The substrate <NUM> may be electrically connected to each of the micro-LEDs <NUM> mounted on the substrate <NUM> in a matrix form, thereby permitting control of the micro-LED <NUM> via a driving signal of the driver <NUM>.

The substrate <NUM> may be a thin film transistor (TFT) substrate, a printed circuit board (PCB), a flexible printed circuit board (flexible PCB), or any combinations thereof.

In addition, the substrate <NUM> may be comprised of various materials, such as a flexible material, glass, or plastic.

The driver <NUM> may control each of the micro-LEDs <NUM>, and may be bonded to an edge region of the substrate <NUM> or a rear surface of the substrate <NUM> by a chip on glass (COG) bonding method or a film on glass (FOG) bonding method to be connected to a substrate <NUM>.

The position at which the driver <NUM> is disposed on the substrate <NUM> and the coupling method are not limited thereto, and may be implemented in various ways.

Hereinafter, a structure in which the reflective layer <NUM> and the light blocking layer <NUM> are formed according to an embodiment of the invention will be described with reference to <FIG>.

<FIG> is a cross-sectional view taken along the line A-A of <FIG>.

As illustrated in <FIG>, the display module <NUM> includes a substrate <NUM>, a plurality of micro-LEDs <NUM> disposed on the substrate <NUM> to radiate light, a reflective layer <NUM> surrounding a lateral surface of each of the plurality of micro-LEDs <NUM> and <NUM> to reflect side light from each of the plurality of micro-LEDs <NUM> and <NUM>, and a light blocking layer <NUM> disposed on the reflective layer <NUM>.

A plurality of micro-LEDs <NUM> are disposed on the substrate <NUM>, however the following description will be based on a structure in which the first and second micro-LEDs <NUM> and <NUM> are disposed on the substrate <NUM> for convenience of explanation. Therefore, the structure in which the plurality of micro-LEDs <NUM> are disposed on the substrate <NUM> may be substantially the same as the structure in which the first and second micro-LEDs <NUM> and <NUM> are disposed on the substrate <NUM>.

The reflective layer <NUM> may be formed of a material having a predetermined light reflectance, and includes a first portion <NUM>-<NUM> surrounding a lateral surface 50c of the micro-LED <NUM>, and a second portion <NUM>-<NUM> filling spaces between a plurality of electrode pads 51a of the micro-LEDs <NUM>, connection pads <NUM> of the substrate <NUM>, and a plurality of soldering members <NUM>.

Specifically, the reflective layer <NUM> is disposed on the substrate <NUM> to surround lateral surfaces of the first and second micro-LEDs <NUM> and <NUM> that are disposed on the substrate <NUM>. That is, the first portion <NUM>-<NUM> of the reflective layer <NUM> contacts the lateral surfaces 50c of the micro-LEDs <NUM> to cover the lateral surfaces 50c of the micro-LEDs <NUM>.

For example, the lateral surface 51c of the first micro-LED <NUM> and the lateral surface 52c of the second micro-LED <NUM> may be covered by the first portion <NUM>-<NUM> of the reflective layer <NUM>.

Accordingly, the side light SL radiated from the lateral surfaces of the micro-LEDs <NUM> may be reflected by the reflective layer <NUM> that permit the light to be radiated towards an upper surface 50b of the micro-LED <NUM>. That is, the side light SL may be reflected by the first portion <NUM>-<NUM> of the reflective layer <NUM>, and radiated towards the upper surface 50b of the micro-LED <NUM>.

For example, as illustrated in <FIG>, the side light SL radiated from the lateral surface 51c of the first micro-LED <NUM> may be reflected by the reflective layer <NUM>, and radiated towards an upper surface 51b of the first micro-LED <NUM>.

Accordingly, the side light SL generated from the lateral surface of the micro-LED <NUM> may be re-directed by the reflective layer <NUM> towards the direction in which the light is radiated from the upper surface 50b of the micro-LED <NUM>, thereby increasing a luminance of the display screen.

In addition, the light from each of the first to third micro-LEDs <NUM>, <NUM>, and <NUM> implementing the red (R), green (G), and blue (B) colors may be increased, thereby improving chromaticness and colorfulness of the display screen, and reducing power consumption for implementing the same level of luminance.

Furthermore, the reflective layer <NUM> may be configured to have a predetermined thermal conductivity. Accordingly, the heat generated from the micro-LED <NUM> may be conducted to the lateral surface thereof by the reflective layer <NUM> disposed on the lateral surface 50c of the micro-LED <NUM>, thereby increasing the heat conduction efficiency.

For example, the lateral surface 51c of the first micro-LED <NUM> may contact the first portion <NUM>-<NUM> of the reflective layer <NUM>, and the heat generated from the lateral surface 51c of the first micro-LED <NUM> may be transferred via the first portion <NUM>-<NUM> of the reflective layer <NUM>.

Accordingly, the reflective layer <NUM> permits effective radiation of the heat generated from the micro-LED <NUM>, thereby reducing the amount of damage to the micro-LED and/or the electronic components disposed near the micro-LED.

In addition, the first portion <NUM>-<NUM> of the reflective layer <NUM> may be formed to have a first thickness t surrounding the lateral surface of the micro-LED <NUM>. Accordingly, the first portion <NUM>-<NUM> of the reflective layer <NUM> may stably fix the lateral surface of the micro-LED <NUM>. Further, the first portion <NUM>-<NUM> may be integrally formed with the second portion <NUM>-<NUM> of the reflective layer <NUM>, thereby stably fixing the micro-LED <NUM> on the substrate <NUM>.

Therefore, the first thickness t may be variously formed to permit the side light SL from the micro-LED <NUM> to be reflected and the micro-LED <NUM> to be stably supported.

The reflective layer <NUM> may be comprised of boron nitride. Boron nitride is a hard ceramic material that is white, has a predetermined light reflectance, is non-conductive, has a high thermal conductivity, and is resistant to thermal shock.

Accordingly, the reflective layer <NUM> may reflect the side light SL from the micro-LED <NUM>, thereby improving a luminance of the display screen, and at the same time, efficiently radiating heat generated from the micro-LED <NUM> based on its high thermal conductivity.

Further, the reflective layer <NUM> may include a material having a predetermined light reflectance such as TiO2 or Si3N4.

In addition, the reflective layer <NUM> may be disposed to expose the upper surfaces 50b of the plurality of micro-LEDs <NUM>. For example, the first portion <NUM>-<NUM> of the reflective layer <NUM> may be disposed so as to not cover the upper surfaces 51b and 52b of the first and second micro-LEDs <NUM> and <NUM>.

An upper surface 90b of the reflective layer <NUM> is, in accordance with the invention, disposed on a level that is equal to or lower than the upper surfaces 50b of the plurality of micro-LEDs <NUM>. For example, a height from the substrate <NUM> to the upper surface 90b of the reflective layer <NUM> may be less than or equal to a height from the substrate <NUM> to the upper surface 51b of the first micro-LED <NUM>.

Accordingly, the reflective layer <NUM> may reflect the side light SL from the micro-LED <NUM> toward the upper surface of the micro-LED <NUM>, while not blocking the light radiated from the upper surface 50b of the micro-LED <NUM>, thereby implementing a predetermined luminance of the display screen.

In addition, the reflective layer <NUM> fills spaces between the plurality of soldering members <NUM> electrically connecting the plurality of micro-LEDs <NUM> and the substrate <NUM>.

Specifically, in order to electrically connect the micro-LED <NUM> and the substrate <NUM>, the micro-LED <NUM> has a plurality of electrode pads 50a, the substrate <NUM> has a plurality of connection pads <NUM>, and the plurality of soldering members <NUM> are disposed between the plurality of electrode pads 50a and the plurality of connection pads <NUM>, respectively. Thereby, the micro-LED <NUM> and the substrate <NUM> may be electrically connected to each other.

Here, the plurality of electrode pads 50a may be elemental constituents that the plurality of micro-LEDs <NUM> have in common.

For example, as illustrated in <FIG>, the plurality of soldering members <NUM> are disposed between the plurality of electrode pads 51a of the first micro-LED <NUM> and the connection pads <NUM> of the substrate <NUM> to electrically connect the first micro-LED <NUM> and the substrate <NUM> to each other.

The second portion <NUM>-<NUM> of the reflective layer <NUM> formed of a non-conductive material fills spaces between the plurality of soldering members <NUM>. Therefore, the reflective layer <NUM> may prevent an electrical short between the plurality of soldering members <NUM>.

Taking into consideration that the second portion <NUM>-<NUM> of the reflective layer <NUM> fills a space under the lower surface of the micro-LED <NUM> and is in contact with the lower surface of the micro-LED <NUM>, the second portion <NUM>-<NUM> of the reflective layer <NUM> may stably fix the micro-LED <NUM> on the substrate <NUM>.

That is, based on the structure in which the reflective layer <NUM> is integrally formed to surround the lateral surface and the lower surface of the micro-LED <NUM>, excluding the upper surface of the micro-LED <NUM>, various physical characteristics of the reflective layer <NUM> may easily be used.

For example, since the reflective layer <NUM> has a predetermined light reflectance, it is possible to reflect the side light SL from the micro-LED <NUM> towards the upper surface of the micro-LED <NUM>. Since the reflective layer <NUM> has a high thermal conductivity, it is possible to efficiently radiate the heat generated from the micro-LED <NUM>. Since the reflective layer <NUM> is comprised of a hard ceramic material that is resistant to thermal shock, it is possible to stably fix the micro-LED <NUM> on the substrate <NUM>, and at the same time, it is possible to protect the micro-LED <NUM> from external impacts.

The light blocking layer <NUM> may be formed between the plurality of micro-LEDs <NUM> to absorb external light and improve a contrast ratio of the display screen.

Specifically, the light blocking layer <NUM> may be formed on the reflective layer <NUM> filled between the plurality of micro-LEDs <NUM>. Thus, the reflective layer <NUM> and the light blocking layer <NUM> may be sequentially stacked between the plurality of micro-LEDs <NUM>.

Accordingly, the light blocking layer <NUM> may separate the first to third micro-LEDs <NUM>, <NUM>, and <NUM>, each emitting light of different color, thereby preventing the colors from being mixed, and may absorb external light, thereby improving a contrast ratio.

In addition, the light blocking layer <NUM> may be formed to fill a space formed in the first portion <NUM>-<NUM> of the reflective layer <NUM>. That is, the light blocking layer <NUM> may be disposed between the plurality of micro-LEDs <NUM> surrounded by the reflective layer <NUM>.

Accordingly, the upper surfaces 50b of the micro-LEDs <NUM> disposed on the substrate <NUM>, the upper surface 90b of the reflective layer <NUM>, and an upper surface 100b of the light blocking layer <NUM> may be planarized.

Therefore, when a protective plate <NUM> is disposed on and contacts the upper surfaces 50b of the micro-LEDs <NUM>, the upper surface 90b of the reflective layer <NUM>, and the upper surface 100b of the light blocking layer <NUM>, the micro-LEDs <NUM>, the reflective layer <NUM>, and the light blocking layer <NUM> may be stably fixed to the protective plate <NUM>.

The light blocking layer <NUM> may also be disposed to expose the upper surfaces 50b of the plurality of micro-LEDs <NUM>. Accordingly, the light blocking layer <NUM> might not absorb light radiated from the upper surfaces 50b of the plurality of micro-LEDs <NUM>, thereby implementing the luminance of the display screen.

In addition, the light blocking layer <NUM> may be comprised of a black matrix photosensitive resin composition for a liquid crystal display including a binder resin, a photo polymerization initiator, a black pigment, and a solvent, or a resin composition including a shielding black pigment.

Hereinafter, the structures of a reflective layer <NUM>' and a light blocking layer <NUM>' according to a modified embodiment of the disclosure will be described with reference to <FIG>.

<FIG> is a cross-sectional view illustrating a reflective layer <NUM>' and a light blocking layer <NUM>' according to a modified embodiment of the disclosure.

The same elements are denoted by the same reference numerals, and overlapping descriptions thereof may be omitted. Specifically, first and second micro-LEDs <NUM> and <NUM> included in a plurality of micro-LEDs <NUM>, a plurality of electrode pads 51a, a plurality of connection pads <NUM>, a substrate <NUM>, and a plurality of soldering members <NUM> may be substantially the same as described above.

The reflective layer <NUM>' may be formed to have a predetermined curved surface <NUM>'e between the plurality of micro-LEDs <NUM>, while surrounding lateral surfaces of the plurality of micro-LEDs <NUM>.

Specifically, when the reflective layer <NUM>' is comprised of boron nitride, the reflective layer <NUM>' may be in a liquid phase at room temperature. In order to form the reflective layer <NUM>', the liquid-phase reflective layer <NUM>' may be injected onto the substrate <NUM>.

At this time, the liquid-phase reflective layer <NUM>' is gradually accumulated on the substrate <NUM>. When the liquid-phase reflective layer <NUM>' contacts a lateral surface 50c of the micro-LED <NUM>, the reflective layer <NUM>' may have a height that is greater at a portion adjacent to the lateral surface 50c of the micro-LED <NUM> due to surface tension.

Accordingly, when the reflective layer <NUM>' is formed as illustrated in <FIG>, the reflective layer <NUM>' an additional polishing process might not be required, thereby improving the manufacturing process, and at the same time, the reflective layer <NUM>' may reflect the side light SL from the micro-LED <NUM>, thereby improving a luminance of the display screen.

The light blocking layer <NUM>' may be disposed between the plurality of micro-LEDs <NUM> and may be formed on the reflective layer <NUM>'. As a result, the light blocking layer <NUM>' may absorb external light and improve a contrast ratio of the display screen.

Hereinafter, the structures of a reflective layer <NUM>" and a light blocking layer <NUM>" according to another modified embodiment of the disclosure will be described with reference to <FIG>.

<FIG> is a cross-sectional view illustrating a reflective layer <NUM>" and a light blocking layer <NUM>" according to a modified embodiment of the disclosure.

When the plurality of micro-LEDs <NUM> are arranged on the substrate <NUM> in a lattice form, the reflective layer <NUM>" may be formed to have the same height as upper surfaces 50b of the plurality of micro-LEDs <NUM>.

In addition, the light blocking layer <NUM>" may be formed in a matrix form on the upper surface of the reflective layer <NUM>" filled between the plurality of micro-LEDs <NUM> arranged in the lattice form. That is, the reflective layer <NUM>" may be disposed to fill spaces between the plurality of micro-LEDs <NUM>, and the light blocking layer <NUM>" may be disposed on the upper surface of the reflective layer <NUM>".

Accordingly, the reflective layer <NUM>" may integrally surround entire lateral surfaces 50c of the plurality of micro-LEDs <NUM>, thereby reflecting the side light SL from the micro-LEDs <NUM> and, at the same time, radiating heat from the micro-LEDs <NUM> and more stably fixing the micro-LEDs <NUM> on the substrate <NUM>.

In addition, the light blocking layer <NUM>" may absorb external light and improve a contrast ratio of the display screen.

Hereinafter, the structure of the reflective layer <NUM> in relation to a plurality of display modules <NUM> and <NUM> will be described in detail with reference to <FIG>.

<FIG> is a top view illustrating a plurality of display modules <NUM> and <NUM> arranged according to an embodiment of the disclosure, <FIG> is a top view illustrating a reflective layer <NUM> formed on the upper surface of <FIG>, and <FIG> is a cross-sectional view taken along the line B-B of <FIG>.

Here, micro-LEDs <NUM> and <NUM> may be substantially the same as the micro-LEDs <NUM>, <NUM> and <NUM> described above, and the colors of light emitted from the micro-LEDs <NUM> and <NUM> may vary. In addition, a plurality of connection pads <NUM> and <NUM> and a plurality of electrode pads 57a and 58a may be substantially the same as the plurality of connection pads <NUM> and <NUM> and the plurality of electrode pads 51a and 52a described above.

As illustrated in <FIG>, first and second display modules <NUM> and <NUM> may be manufactured in the form of a module having a predetermined size, and the first and second display modules <NUM> and <NUM> may be arranged on an array plate <NUM> to thereby implement a display screen in various sizes and forms.

Thereafter, as illustrated in <FIG>, a reflective layer <NUM> may be formed on the array plate <NUM> and the first and second display modules <NUM> and <NUM> disposed on the array plate <NUM>.

At this time, as illustrated in <FIG>, the reflective layer <NUM> includes, in accordance with the invention, a third portion <NUM>-<NUM> filling a space D1 between the first and second display modules <NUM> and <NUM>.

The third portion <NUM>-<NUM> may be integrally formed on the array plate <NUM> and the first and second display modules <NUM> and <NUM> disposed on the array plate <NUM>.

That is, the third portion <NUM>-<NUM> of the reflective layer <NUM> formed on each of the plurality of display modules <NUM> and <NUM> is integrally formed.

Accordingly, when the reflective layer <NUM> is cured, the reflective layer <NUM> may fix the plurality of display modules <NUM> and <NUM> at predetermined positions of the array plate <NUM>.

In addition, the first portion <NUM>-<NUM>, the second portion <NUM>-<NUM>, and the third portion <NUM>-<NUM> of the reflective layer <NUM> are integrally formed. Accordingly, the reflective layer <NUM> may structurally fix the plurality of micro-LEDs <NUM> and the plurality of display modules <NUM>.

The light blocking layer <NUM> is, in accordance with the invention, formed above the space D1 between the first and second display modules <NUM> and <NUM>.

Accordingly, the light blocking layer <NUM> may fill or cover a portion corresponding to a seam that may appear on the display screen due to the space D1 between the first and second display modules <NUM> and <NUM>, thereby covering the seam on the display screen so as to be seamless.

In addition, as illustrated in <FIG>, since the reflective layer <NUM> and the light blocking layer <NUM> are disposed to expose the upper surfaces 50b of the plurality of micro-LEDs <NUM>, it is possible to prevent light emitted from the upper surfaces 50b of the plurality of micro-LEDs <NUM> from being blocked.

Hereinafter, a process of manufacturing a display module <NUM> according to an embodiment of the disclosure will be described in detail with reference to <FIG>.

<FIG> are schematic cross-sectional views illustrating a process of manufacturing a display module <NUM> according to an embodiment of the disclosure.

As illustrated in <FIG>, a plurality of micro-LEDs <NUM> is disposed on a substrate <NUM>. For example, first and second micro-LEDs <NUM> and <NUM> may be disposed on the substrate <NUM> at a predetermined distance.

At this time, a plurality of soldering members <NUM> is disposed between a plurality of electrode pads 51a and 52a of each micro-LED <NUM> and a plurality of connection pads <NUM> and <NUM> of the substrate <NUM>, respectively. Accordingly, the plurality of micro-LEDs <NUM> and the substrate <NUM> may be electrically and physically connected to each other.

Thereafter, as illustrated in <FIG>, a reflective layer <NUM> is formed on the substrate <NUM> to surround a lateral surface of each of the plurality of micro-LEDs <NUM>. That is, the liquid-phase state reflective layer <NUM> may be applied onto the substrate <NUM> and the plurality of micro-LEDs <NUM> disposed on the substrate <NUM>.

In addition, the reflective layer <NUM> may be applied in a liquid phase M onto the substrate <NUM> and the plurality of micro-LEDs <NUM> through a dispenser <NUM> so as to completely surround the plurality of micro-LEDs <NUM>.

Here, the dispenser <NUM> may form the reflective layer <NUM>, while moving above the substrate <NUM> in a predetermined direction.

In addition, the reflective layer <NUM> may be integrally applied onto the substrate <NUM> and the plurality of micro-LEDs <NUM>.

In a state where the reflective layer <NUM> has been applied onto the substrate <NUM> to surround the plurality of micro-LEDs <NUM>, the reflective layer <NUM> may be heat-cured by applying heat to the reflective layer <NUM>.

Thereafter, as illustrated in <FIG>, a light blocking layer <NUM> may be formed on the heat-cured reflective layer <NUM>. Here, the light blocking layer <NUM> may be applied in a liquid-phase state, and may then be thermally cured and solidified.

Next, the portions above the plurality of micro-LEDs <NUM> may be polished so that the upper surfaces 50b of the plurality of micro-LEDs <NUM> are exposed. Specifically, the polishing may be performed such that the respective upper surfaces of the micro-LEDs <NUM>, the reflective layer <NUM>, and the light blocking layer <NUM> are planarized.

For example, on the basis of the line C of <FIG> corresponding to the upper surfaces 50b of the plurality of micro-LEDs <NUM>, the portions of the reflective layer <NUM> and the light blocking layer <NUM> formed above the line C may be removed.

At this time, a chemical mechanical polishing (CMP) process may be used for the polishing process.

Accordingly, as illustrated in <FIG>, it may be implemented that the reflective layer <NUM> surrounds the lateral surfaces 50c of the plurality of micro-LEDs <NUM> in the state where the upper surfaces 50b of the plurality of micro-LEDs <NUM> are exposed.

Hereinafter, a manufacturing process for forming the reflective layer <NUM>' and the light blocking layer <NUM>' according to the modified embodiment of the disclosure illustrated in <FIG> will be described with reference to <FIG>.

<FIG> are schematic cross-sectional views illustrating a process of manufacturing a display module <NUM>' according to a modified embodiment of the disclosure.

As illustrated in <FIG>, the liquid-phase reflective layer <NUM>' may be applied onto the substrate <NUM> and the plurality of micro-LEDs <NUM> mounted on the substrate <NUM> through a dispenser <NUM>'.

At this time, the dispenser <NUM>' may continuously inject the liquid-phase reflective layer <NUM>' onto a portion of the substrate <NUM>.

The reflective layer <NUM>' may be gradually higher from the upper surface 70b of the substrate <NUM>, and filled to surround the micro-LED <NUM> from a lower portion of the micro-LED <NUM>.

Accordingly, the reflective layer <NUM>' is gradually accumulated on the substrate <NUM>. When the liquid-phase reflective layer <NUM>' is in contact with the lateral surface 50c of the micro-LED <NUM>, the reflective layer <NUM>' may have a height that is greater at a portion adjacent to the lateral surface 50c of the micro-LED <NUM> due to surface tension.

Accordingly, when the reflective layer <NUM>' is formed as illustrated in <FIG>, the reflective layer <NUM>' might not require an additional polishing process, thereby improving the manufacturing process, and at the same time, the side light SL from the micro-LED <NUM> may be reflected, thereby improving a luminance of the display screen.

As shown in <FIG>, light blocking layer <NUM>' may be disposed between the plurality of micro-LEDs <NUM> and may be formed on the reflective layer <NUM>'. As a result, the light blocking layer <NUM>' may absorb external light and improve a contrast ratio of the display screen.

Claim 1:
A display module (<NUM>, <NUM>) and an adjacent display module (<NUM>, <NUM>), each of the display modules comprising:
a substrate (<NUM>);
a plurality of micro light-emitting diodes, micro-LEDs, (<NUM>, <NUM>, <NUM>) disposed on the substrate (<NUM>), and configured to radiate light;
a plurality of electrode pads (57a, 58a) of the micro-LEDs;
a plurality of connection pads (<NUM>, <NUM>) on the substrate (<NUM>);
a plurality of soldering members (<NUM>) configured to electrically connect the plurality of micro-LEDs and the substrate (<NUM>) to each other and disposed between the plurality of electrode pads (57a, 58a) and the plurality of connection pads (<NUM>, <NUM>); the display module (<NUM>, <NUM>) and the adjacent display module (<NUM>, <NUM>) further comprising:
a reflective layer (<NUM>) surrounding a lateral surface of each of the plurality of micro-LEDs ; and
a light blocking layer (<NUM>) disposed on the reflective layer (<NUM>),
wherein an upper surface of the reflective layer (<NUM>) is lower than or planar with upper surfaces of the plurality of micro-LEDs, and
wherein the reflective layer (<NUM>) comprises a first portion (<NUM>-<NUM>) surrounding and contacting lateral surfaces (50c, 51c, 52c) of the plurality of micro-LEDs, a second portion (<NUM>-<NUM>) filling spaces between the plurality of electrode pads (57a, 58a), the plurality of connection pads (<NUM>, <NUM>) and the plurality of soldering members (<NUM>), and a third portion (<NUM>-<NUM>) filling a space between the display module (<NUM>) and adjacent display module (<NUM>),
wherein the first portion (<NUM>-<NUM>), the second portion (<NUM>-<NUM>) and the third portion (<NUM>-<NUM>) of the reflective layer (<NUM>) are integrally formed,
wherein the light blocking layer (<NUM>) is formed above the space between the display module (<NUM>, <NUM>) and the adjacent display module (<NUM>, <NUM>).