Patent Description:
A display apparatus is a type of output apparatus that visually displays images and data information, such as characters, figures, etc. Recently, there has been increased demand for a display apparatus with high brightness, high resolution, a large-screen, high efficiency, and low power. An organic light emitting diode (OLED) panel has many of these characteristics. However, the OLED panel still has many issues that have to be solved, such as improving yield, securing reliability according to enlargement, and securing durability against external environmental conditions such as water. <CIT> discloses a display device including light emitting units and a light absorbing unit. <CIT> relates to a display unit including light emitting units, light transmissive members covering the light emitting elements, and light absorbing members covering surfaces of the light-transmissive members.

In regard of a new product for replacing or complementing liquid crystal display (LCD) and OLED panels, a technique for forming a panel by mounting light-emitting devices of emitting light of red (R), green (G), and blue (B) colors directly on a substrate is being studied. However, the technique has many difficulties in a process of transferring light-emitting devices with a size of several µm to hundreds of µm, carried from a wafer, onto a substrate. A technique for physically protecting the light-emitting devices against optical distortion or loss after mounting the light-emitting devices on the substrate also has a great difficulty. Also, a technique for improving the picture quality of the display apparatus, in addition to a technique for protecting the light-emitting devices, is needed.

Therefore, it is an aspect of the disclosure to provide a display module with an improved structure capable of preventing boundary lines or seams between neighboring substrates from being shown when a large screen is implemented by arranging a plurality of substrates in a matrix form, a display apparatus, and a manufacturing method of the display apparatus.

It is another aspect of the disclosure to provide a display module capable of physically protecting light-emitting devices mounted on a substrate and improving transmittance of light emitted from the light-emitting devices to improve picture quality, a display apparatus, and a manufacturing method of the display apparatus.

In accordance with an aspect of the disclosure, there is provided a display module that includes: a plurality of substrates; a plurality of light-emitting devices mounted on each of the plurality of substrates; a plurality of transparent resins that surrounds upper surfaces and side surfaces of the plurality of light-emitting devices, the plurality of transparent resins not covering lower surfaces of the light emitting devices; a frame supporting the plurality of substrates; and an opaque molding layer that is disposed on the plurality of substrates between the plurality of transparent resins and covers partial surfaces of the plurality of transparent resins, wherein the opaque molding layer covers a portion of a top surface of each of the plurality of transparent resins and does not cover areas of the plurality of transparent resins corresponding to light-emitting surfaces of the plurality of light-emitting device.

The opaque molding layer may cover side surfaces of the plurality of transparent resins.

A height of one of the plurality of light-emitting devices from a surface of a first substrate from among the plurality of substrates may be a first height, a height of one of the plurality of transparent resins from the surface may be a second height, and a height of the opaque molding layer from the surface may be greater than or equal to the first height and less than or equal to the second height.

The display module may further include a transparent layer that covers the opaque molding layer.

The plurality of transparent resins may be arranged at regular intervals and surrounds the plurality of light-emitting devices, respectively.

The plurality of light-emitting devices may form a plurality of unit pixels, each of the plurality of unit pixels may include at least two of the plurality of light-emitting devices, and the plurality of transparent resins may respectively surround the plurality of unit pixels.

Each of the plurality of transparent resins may surround at least two of the plurality of light-emitting devices.

In accordance with the invention, there is provided a display apparatus that includes:.

The opaque molding layer may surround side surfaces of the plurality of transparent resins.

The plurality of transparent resins may further include a diffusion agent for diffusing light emitted from the plurality of light-emitting devices.

Each of the plurality of transparent resins includes an area that is exposed by the opaque molding layer, and the area of each of the plurality of transparent resins may include a micro protrusion.

In accordance with the invention, a method of manufacturing a display apparatus includes: adjacently arranging a plurality of substrates on which a plurality of light-emitting devices is mounted; applying a plurality of transparent resins on the plurality of light-emitting devices; and applying an opaque molding layer on the plurality of substrates between the plurality of transparent resins to fill gaps between the plurality of transparent resins and cover partial surfaces of the plurality of transparent resins, wherein the applying of the opaque molding layer comprises applying the opaque molding layer such that the opaque molding layer covers a portion of a top surface of each of the plurality of transparent resins and does not cover areas of the plurality of transparent resins corresponding to light-emitting surfaces of the plurality of light-emitting devices, wherein the light-emitting surfaces (50a) are the upper surfaces of the light-emitting devices (<NUM>).

The applying the opaque molding layer may include applying the opaque molding layer such that the opaque molding layer covers side surfaces of the plurality of transparent resins.

A height of one of the plurality of light-emitting devices from a surface of a first substrate from among the plurality of substrates may be a first height, a height of one of the plurality of transparent resins from the surface may be a second height, and the applying the opaque molding layer may include applying the opaque molding layer such that a height of the opaque molding layer is greater than or equal to the first height and less than or equal to the second height.

The applying the opaque molding layer may include: applying an opaque resin on a surface of a transparent layer that corresponds to an entire area of the plurality of substrates; and attaching the transparent layer on which the opaque resin is applied to the plurality of substrates on which the plurality of transparent resins is disposed.

The method may further include removing the transparent layer.

The applying the opaque molding layer may include: applying an opaque resin on the plurality of substrates between the plurality of transparent resins to fill the gaps between the plurality of transparent resins; and cutting the opaque resin to planarize a front surface of the opaque molding layer.

The applying the plurality of transparent resins may include forming a micro protrusion in a surface of each of the plurality of transparent resins that is exposed by the opaque molding layer.

In the display module, the display apparatus, and the manufacturing method of the display apparatus, according to the embodiments, the plurality of light-emitting devices mounted on the substrates may be physically protected, and the picture quality of the display apparatus may be improved due to an improvement of optical performance.

Also, in the display module, the display apparatus, and the manufacturing method of the display apparatus, according to the embodiments, when the substrates are tiled to implement a large screen, the boundary lines or seams between the neighboring substrates may be hidden.

Accordingly, by seamlessly assembling a large number of substrates, a display apparatus having a large screen size meeting a consumer's requirements may be provided.

The disclosure may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Also, parts in the drawings unrelated to the detailed description may be omitted for clarity. Like reference numerals in the drawings denote like elements.

An expression used in the singular encompasses the expression of the plural, unless it is clearly provided otherwise. Also, it will be understood that, the terms "1st," "first," "2nd," or "second," may use corresponding components regardless of importance or order and are used to distinguish a component from another without limiting the components.

In the present specification, it is to be understood that the terms such as "comprising", "including" or "having", etc., indicate the existence of the features, numbers, operations, components, parts, or combinations thereof disclosed in the specification, and are not intended to preclude the possibility that one or more other features, numbers, operations, components, parts, or combinations thereof may exist or may be added.

In the following description, the terms "front surface", "rear surface", "upper portion" and "lower portion" are defined based on the drawings, and the shapes and positions of the corresponding components are not limited by the terms.

<FIG> is a perspective view of a display apparatus according to an embodiment. In <FIG>, "X" represents a front-back direction, "Y" represents a left-right direction, and "Z" represents an up-down direction.

As shown in <FIG>, a display apparatus <NUM> may be an apparatus for displaying information, materials, data, etc. in the form of characters, figures, graphs, images, etc. The display apparatus <NUM> may be implemented as a television (TV), a personal computer (PC), a mobile device, a digital signage, etc. The display apparatus <NUM> may be installed on a stand to sit on the ground or installed on a wall.

The display apparatus <NUM> includes a cabinet <NUM>, a plurality of display modules 30A to <NUM> that are installed in the cabinet <NUM>, and a plurality of frames <NUM> and <NUM> for supporting the cabinet <NUM>, a plurality of substrates <NUM>, and the plurality of display modules 30A to <NUM>. The cabinet <NUM> may support the plurality of display modules 30A to <NUM>, and form a part of an outer appearance of the display apparatus <NUM>.

The plurality of display modules 30A to <NUM> may be arranged in the form of a MxN matrix in up, down, left, and right directions to be adjacent to each other. In <FIG>, <FIG> display modules 30A to <NUM> may be coupled in the form of a 3x4 matrix with the cabinet <NUM>. However, the quantity and arrangement of the plurality of display modules 30A to <NUM> are not limited, and may change variously.

As such, the display apparatus <NUM> according to the disclosure may be implemented as a large screen by tiling the plurality of display modules 30A to <NUM>.

Also, the number of the frames <NUM> and <NUM> is not limited. Some display modules, for example display modules 30A to 30F among the plurality of display modules 30A to <NUM>, may be installed in the cabinet <NUM> by the frame <NUM>, and the other display modules, for example display modules <NUM> to <NUM>, may be installed in the cabinet <NUM> by the frame <NUM>. Also, each of the plurality of display modules 30A to <NUM> may include a plurality of substrates <NUM>, and the plurality of substrates <NUM> may be independently supported by the frames <NUM> and <NUM>.

A cabinet coupling portion <NUM> may be provided in the cabinet <NUM>. A frame coupling portion <NUM> may be provided in the frames <NUM> and <NUM>. The cabinet coupling portion <NUM> and frame coupling portion <NUM> may be used to install the display modules 30A to <NUM> in the cabinet <NUM>. The cabinet coupling portion <NUM> may be coupled with the frame coupling portion <NUM> by various methods, such as a magnetic force using a magnet, a mechanical insertion structure, etc..

The display apparatus <NUM> may further include a control board for driving the plurality of display modules 30A to <NUM>, and a power supply for supplying power to the plurality of display modules 30A to <NUM>.

The plurality of display modules 30A to <NUM> may be flat or curved. Also, the plurality of display modules 30A to <NUM> may have a variable curvature.

<FIG> is a front view showing a plurality of display modules arranged in a matrix according to an embodiment. <FIG> is a front view of a display module according to an embodiment, and <FIG> is a perspective view of a display module according to an embodiment.

Each of the display modules 30A to <NUM> illustrated in <FIG> includes a single substrate <NUM>. However, embodiments are not limited thereto, and each of the display modules 30A to <NUM> includes a plurality of substrates <NUM>. Also, the plurality of display modules 30A to <NUM> may be connected to form a display module. In other words, the display apparatus <NUM> includes a plurality of substrates <NUM> on which a plurality of light-emitting devices <NUM> is mounted. However, in <FIG>, a single substrate <NUM> is shown for convenience of description.

Referring to <FIG>, the display modules 30A to <NUM> include the substrate <NUM>, and the plurality of light-emitting devices <NUM> mounted on an installation surface <NUM> of the substrate <NUM>.

The substrate <NUM> may be made of polyimide (PI), FR4, glass, etc. On the installation surface <NUM> of the substrate <NUM>, a pattern forming a driving circuit and a plurality of electrodes electrically connected to the plurality of light-emitting devices <NUM> is formed. The substrate <NUM> may include a thin film transistor (TFT), and first and second pad electrodes to which the light-emitting devices <NUM> are electrically connected may be formed on an upper surface of the substrate <NUM>. The substrate <NUM> may include a printed circuit board (PCB), a metal core PCB (MCPCB), a flexible PCB (FPCB), etc..

The light-emitting devices <NUM> include an n-type semiconductor, an active layer, a p-type semiconductor, a first contact electrode, and a second contact electrode, and may be a flip chip form in which the first contact electrode and the second contact electrode are arranged toward the same direction. Also, the first and second contact electrodes of the light-emitting devices <NUM> may be respectively soldered at the electrodes formed on the substrate <NUM>. Also, the light-emitting devices <NUM> may be bonded on the substrate <NUM> by a bonding material made of a resin (for example, epoxy, silicon, urethane, and the like), an anisotropic conductive film (ACF), etc..

The light-emitting devices <NUM> include light-emitting diodes (LEDs). The light-emitting devices <NUM> are manufactured with an inorganic material. Accordingly, the light-emitting devices <NUM> may have high durability and long lifecycles compared to OLEDs that are manufactured with an organic material. Additionally, the light-emitting devices <NUM> may also have power efficiency that is several times greater than that of the OLEDs.

The light-emitting devices <NUM> may include a red light-emitting device <NUM>, a green light-emitting device <NUM>, and a blue light-emitting device <NUM>. In the light-emitting devices <NUM>, the red light-emitting device <NUM>, the green light-emitting device <NUM>, and the blue light-emitting device <NUM> may be grouped into one unit and mounted on the substrate <NUM>.

A group of the red light-emitting device <NUM>, the green light-emitting device <NUM>, and the blue light-emitting device <NUM> may form a pixel. The red light-emitting device <NUM>, the green light-emitting device <NUM>, and the blue light-emitting device <NUM> may each form a sub pixel. Each of the display modules 30A to <NUM> may display an image by selectively turning on/off, or controlling brightness levels of sub pixels forming a plurality of pixels. That is, the display modules 30A to <NUM> may be defined as multi-pixel modules or multi-pixel packages.

As shown in <FIG> and <FIG>, the red light-emitting device <NUM>, the green light-emitting device <NUM>, and the blue light-emitting device <NUM> may be arranged in a line and spaced apart from each other. Also, as shown in <FIG>, the red light-emitting device <NUM>, the green light-emitting device <NUM>, and the blue light-emitting device <NUM> may be arranged in a horizontal direction and a vertical direction to form a '<IMG>' shape. However, arrangements of the light-emitting devices <NUM> are not limited to these, and the light-emitting devices <NUM> may be arranged in another shape. Also, each pixel may include additional sub pixels formed by additional light-emitting devices, such as a white light-emitting device or a cyan light-emitting device.

The light-emitting devices <NUM> may be picked up from a wafer and then transferred directly on the substrate <NUM>. The light-emitting devices <NUM> may be picked up and transferred by an electrostatic method using an electrostatic head or an adhesive method using an elastic polymer material, such as polydimethylsiloxane (PDMS) or silicon, as a head. Horizontal lengths, vertical lengths, and heights of the light-emitting devices <NUM> may be several µm to hundreds of µm. For example, the light emitting device <NUM> may be a micro LED having a size of <NUM> to <NUM>. The height of the light emitting device <NUM> may be <NUM> to <NUM>. The largest value among the horizontal length, the vertical length, and the height may be <NUM> or less.

<FIG> are cross-sectional views of display modules according to different embodiments.

Referring to <FIG>, a display module 30A includes a plurality of transparent resins <NUM> surrounding the light-emitting devices <NUM>, and an opaque molding layer <NUM> surrounding the transparent resins <NUM> and covering a front surface of the substrate <NUM>. When the display module 30A includes a plurality of substrates <NUM>, the plurality of substrates <NUM> may be arranged to be adjacent to each other, and a plurality of light-emitting devices <NUM> may be mounted on each substrate <NUM>. In this case, the opaque molding layer <NUM> covers partial surfaces of the transparent resins <NUM> and surfaces of the substrates <NUM> between the plurality of transparent resins <NUM>.

On a front surface of the opaque molding layer <NUM>, a transparent layer <NUM> may be further provided to protect the light-emitting devices <NUM> and the substrates <NUM> covered with the opaque molding layer <NUM>. However, the transparent layer <NUM> may be not included in the display module 30A, as shown in <FIG>.

As described above, the light-emitting devices <NUM> may be arranged in various shapes on the substrate <NUM>. That is, the red light-emitting device <NUM>, the green light-emitting device <NUM>, and the blue light-emitting device <NUM> constituting one pixel may be arranged in a line or in a '<IMG>' shape.

<FIG> show cross-sections I-I' of the display module 30A in which the red light-emitting device <NUM>, the green light-emitting device <NUM>, and the blue light-emitting device <NUM> constituting one pixel are arranged in a '<IMG>' shape on the substrate <NUM>, as shown in <FIG>.

Referring to <FIG>, the transparent resin <NUM> is provided on each of the light-emitting devices <NUM> mounted on the substrate <NUM>. The transparent resin <NUM> is applied at regular intervals to surround each of the light-emitting devices <NUM>. That is, the transparent resin <NUM> surrounds each of the red light-emitting device <NUM>, the green light-emitting device <NUM>, and the blue light-emitting device <NUM>.

The transparent resins <NUM> surrounds the light-emitting devices <NUM> so that the transparent resins <NUM> surround upper surfaces (also, referred to as light-emitting surfaces) 50a and side surfaces of the light-emitting devices <NUM>, but do not cover lower surfaces of the light-emitting devices <NUM>. More specifically, because the light-emitting devices <NUM> are mounted on the substrate <NUM>, the lower surfaces of the light-emitting devices <NUM> being in direct/indirect contact with the installation surface <NUM> of the substrate <NUM> may be not covered by the transparent resins <NUM>.

Also, referring to <FIG>, multiple light-emitting devices may form a unit pixel. The transparent resin <NUM> may surround the light-emitting devices constituting the unit pixel among the light-emitting devices <NUM>. More specifically, the transparent resin <NUM> may surround the red light-emitting device <NUM>, the green light-emitting device <NUM>, and the blue light-emitting device <NUM> constituting one pixel among the light-emitting devices <NUM> altogether. That is, the transparent resin <NUM> may be applied for each unit pixel. In this case, likewise, the transparent resin <NUM> may cover the upper and side surfaces of the light-emitting devices <NUM> constituting a unit pixel except for the lower surfaces of the light-emitting devices <NUM> being in contact with the substrate <NUM>. The transparent resin <NUM> may be formed to a predetermined height from the light-emitting surfaces 50a of the light-emitting devices <NUM> toward the front direction X of the display modules 30A to <NUM>.

The transparent resin <NUM> may be applied, coated, or jetted through a transparent resin supplying apparatus <NUM> to surround the light-emitting devices <NUM>. However, a method of supplying the transparent resin <NUM> is not limited to this. The transparent resin <NUM> may be made of acrylic urethane, epoxy, silicon, polyester, or the like, although embodiments are not limited thereto.

The opaque molding layer <NUM> surrounds the plurality of transparent resins <NUM> and covers the front surface of the substrate <NUM>. More specifically, the opaque molding layer <NUM> covers partial surfaces of the plurality of transparent resins <NUM> and fill gaps between the plurality of transparent resins <NUM>. In other words, the opaque molding layer <NUM> covers the plurality of transparent resins <NUM> so that light is emitted toward the front direction X of the display modules 30A to <NUM> through the light-emitting surfaces 50a of the plurality of light-emitting devices <NUM>. The opaque molding layer <NUM> covers side surfaces of the plurality of transparent resins <NUM> corresponding to the respective side surfaces 50b of the plurality of light-emitting devices <NUM>. The opaque molding layer <NUM> exposes at least a portion of a top surface of the plurality of transparent resins <NUM>. When the display module 30A includes a plurality of substrates <NUM>, the opaque molding layer <NUM> may cover front surfaces of the substrates <NUM> to cover boundary lines or seams G that exist between the substrates <NUM>.

For example, a height of the opaque molding layer <NUM> may be greater than or equal to a first height h1 and less than or equal to a second height h2 from the surface(installation surface <NUM>) of the substrate <NUM>. More specifically, a height of the opaque molding layer <NUM> may be greater than or equal to the first height h1 corresponding to a height of the plurality of light-emitting devices <NUM> from the installation surface <NUM> of the substrate <NUM>, and may be less than or equal to the second height h2 corresponding to a height of the plurality of transparent resins <NUM> from the surface(installation surface <NUM>) of the substrate <NUM>.

The first height h1 and the second height h2 may change according to designs. Also, the second height h2 may be lower than the height of the transparent resin <NUM> from the installation surface <NUM> of the substrate <NUM>. Because light needs to be emitted through the light-emitting surfaces 50a of the light-emitting devices <NUM>, areas of the transparent resins <NUM> corresponding to the light-emitting surfaces 50a of the light-emitting devices <NUM> are not covered with the opaque molding layer <NUM>.

Referring to <FIG>, the light-emitting devices <NUM> may be bonded on the substrate <NUM> through a bonding material <NUM> made of a resin (for example, epoxy, silicon, urethane, and the like), anisotropic conductive film (ACF), etc. The bonding material <NUM> may have a predetermined thickness. For example, the bonding material <NUM> may be applied on the substrate <NUM>, and then, the light-emitting devices <NUM> may be mounted on the bonding material <NUM>. When the light-emitting devices <NUM> are mounted on the bonding material <NUM>, a pressure may be applied to the bonding material <NUM>. Accordingly, the light-emitting devices <NUM> may be mounted in such a way to be stuck in the bonding material <NUM>. In this case, the transparent resins <NUM> may be applied on the bonding material <NUM> to surround the light-emitting devices <NUM>. Accordingly, the transparent resins <NUM> surround the light-emitting surfaces 50a of the light-emitting devices <NUM> and some portions of the side surfaces 50b of the light-emitting devices <NUM>, without surrounding the entire of the side surfaces 50b of the light-emitting devices <NUM>. Also, the opaque molding layer <NUM> may be provided on the bonding material <NUM> to surround the side surfaces of the transparent resins <NUM> and cover the front surface of the substrate <NUM>.

As such, when the light-emitting devices <NUM> are surrounded by the transparent resins <NUM>, the light-emitting devices <NUM> may be protected, and loss of light emitted from the light-emitting devices <NUM> may be reduced. When the light-emitting devices <NUM> and the side surfaces of the transparent resins <NUM> are surrounded by the opaque molding layer <NUM>, light-emitting areas of the light-emitting devices <NUM> may be toward the front direction of the display module. That is, light emitted from the side surfaces 50b of the light-emitting devices <NUM> may be blocked or absorbed by the opaque molding layer <NUM>. Accordingly, when the plurality of substrates <NUM> or the plurality of display modules 30A to <NUM> on which the plurality of light-emitting devices <NUM> are mounted are tiled, boundary lines or seams G between neighboring substrates or display modules may not be visible.

The transparent layer <NUM> may be provided on the opaque molding layer <NUM> to protect the light-emitting devices <NUM> against optical distortion. Also, the transparent layer <NUM> may planarize the opaque molding layer <NUM>. A parting agent may be interposed between the transparent layer <NUM> and the opaque molding layer <NUM>, and after the opaque molding layer <NUM> is hardened, the transparent layer <NUM> may be removed. The transparent layer <NUM> may be formed of a transparent material, such as glass, transparent plastic, an optical film, or the like.

<FIG> illustrates a display module according to an embodiment. As illustrated, the display module 30A may not include transparent layer <NUM>.

<FIG> shows micro protrusions formed in a surface of a transparent resin according to an embodiment.

Referring to <FIG>, a plurality of micro protrusions <NUM> may be formed in a surface of the transparent resin <NUM>. For example, the micro protrusions <NUM> forming an uneven pattern may be formed in a surface of the transparent resin <NUM> corresponding to the light-emitting surface 50a of the light-emitting device <NUM>. The micro protrusions <NUM> formed in the surface of the transparent resin <NUM> may refract light emitted from the light-emitting device <NUM>, and accordingly, viewing angle characteristics of the display module may be improved.

According to an embodiment, the transparent resin <NUM> may include a diffusion agent or a scattering agent for diffusing light emitted from the light-emitting device <NUM>. The diffusion agent or the scattering agent included in the transparent resin <NUM> may diffuse light emitted from the light-emitting device <NUM> to thereby reduce light loss and improve viewing angle characteristics of the display module.

According to an embodiment, the transparent resin <NUM> may include a light-absorbing pigment. When the transparent resin <NUM> includes a light-absorbing pigment, a wavelength of light emitted from the light-emitting device <NUM> may be shortened, and accordingly, color purity may be improved.

According to an embodiment, the transparent resin <NUM> may include a fluorescent material. The fluorescent material may change a color of light emitted from the light-emitting device <NUM>. For example, when a blue light-emitting device <NUM> is mounted on the substrate <NUM>, a fluorescent material may be mixed in the transparent resin <NUM> surrounding the blue light-emitting device <NUM> so that red or green light is emitted.

Hereinafter, a method of manufacturing a display apparatus according to an embodiment will be described.

<FIG> briefly shows a method of manufacturing a display apparatus according to an embodiment.

Referring to <FIG>, a method of manufacturing the display apparatus <NUM> includes operation <NUM> of mounting a plurality of light-emitting devices <NUM> on a plurality of substrates <NUM> and arranging the plurality of substrates <NUM> to be adjacent to each other.

Then, a transparent resin <NUM> is applied to surround the light-emitting devices <NUM>, in operation <NUM>. The transparent resin <NUM> may be applied at regular intervals to surround each of the light-emitting devices <NUM>. That is, the transparent resin <NUM> may individually surround a red light-emitting device <NUM>, a green light-emitting device <NUM>, and a blue light-emitting device <NUM>.

Also, the transparent resin <NUM> may surround multiple light-emitting devices constituting a unit pixel among the light-emitting devices <NUM>. More specifically, the transparent resin <NUM> may surround a unit pixel that includes a red light-emitting device <NUM>, a green light-emitting device <NUM>, and a blue light-emitting device <NUM>. The transparent resin <NUM> may be similarly applied for each unit pixel. In this case, the transparent resin <NUM> may be formed to a predetermined height from the light-emitting surfaces 50a of the light-emitting devices <NUM> toward the front direction X of display modules 30A to <NUM>.

The transparent resin <NUM> may be applied, coated, or jetted through a transparent resin supplying apparatus <NUM> to surround the light-emitting devices <NUM>. However, a method of supplying the transparent resin <NUM> is not limited to this.

Also, as described above, the transparent resin <NUM> surrounds the upper surfaces 50a and side surfaces of the light-emitting devices <NUM> and does not surround the lower surfaces of the light-emitting devices <NUM>. More specifically, because the light-emitting devices <NUM> are mounted on the substrate <NUM>, the lower surfaces of the light-emitting devices <NUM> being in direct/indirect contact with the installation surface <NUM> of the substrate <NUM> are not covered by the transparent resin <NUM>.

Then, an opaque molding layer <NUM> is applied to cover partial surfaces of the transparent resins <NUM> and fill gaps between the transparent resins <NUM> in operation <NUM>. That is, the opaque molding layer <NUM> is applied to surround the plurality of transparent resins <NUM> and cover the front surfaces of the substrates <NUM> such that light is emitted through the light-emitting surfaces 50a of the light-emitting devices <NUM>. Accordingly, boundary lines or seams G that exist between the substrates <NUM> may be covered with the opaque molding layer <NUM>.

The opaque molding layer <NUM> may be made of a liquid or solid material. Also, a black molding layer may be implemented by a film type material. For example, an opaque resin may be supplied to form the opaque molding layer <NUM>. The opaque resin may be applied, coated, or jetted on the transparent layers <NUM> or the substrates <NUM> through an opaque resin supplying apparatus. However, a method of forming the opaque molding layer <NUM> is not limited to this.

The opaque molding layer <NUM> may include a base material and a black pigment. The base material may include at least one of a thermosetting material and a photosensitive material. For example, the thermo setting material may include at least one of silicon, epoxy, ethylene-vinyl acetate copolymer (EVA), polyvinyl butyral (PVA), and urethane. The photosensitive material may be a photosensitive material to which a photolithography process may be applied.

The opaque molding layer <NUM> may include a material that is a black color for increasing a light absorption effect. The opaque molding layer <NUM> may include an inorganic material, an organic material, a metal, etc. For example, the opaque molding layer <NUM> may be include a material, such as carbon black, a polyene pigment, an azo pigment, an azomethine pigment, a diimmonium pigment, a phthalocyanine pigment, a quinone pigment, an indigo pigment, a thioindigo pigment, a dioxadin pigment, a quinacridone pigment, an isoindolinone pigment, a metal oxide, a metal complex, aromatic hydrocabos, and the like.

When the opaque molding layer <NUM> is implemented to have a black color, a black impression may be maintained in a turned-off state of the display apparatus <NUM>, and in a turned-on state of the display apparatus <NUM>, an effect of improving picture quality and a contrast ratio may be expected.

As such, when the light-emitting devices <NUM> are surrounded by the transparent resins <NUM>, the light-emitting devices <NUM> may be protected, and loss of light emitted from the light-emitting devices <NUM> may be reduced. Also, when the opaque molding layer <NUM> surrounds the side surfaces of the light-emitting devices <NUM> and the transparent resins <NUM> and covers the front surfaces of the plurality of substrates <NUM>, the boundary lines or seams G between neighboring display modules may be prevented from being shown.

<FIG> is a view for describing a first method of manufacturing a display apparatus according to an embodiment, and <FIG> is a view for describing a second method of manufacturing a display apparatus according to an embodiment.

Referring to <FIG> and <FIG>, the methods of manufacturing the display apparatus <NUM> include operations <NUM> and <NUM> of mounting light-emitting devices <NUM> on a plurality of substrates <NUM> and arranging the plurality of substrates <NUM> to be adjacent to each other.

Then, a transparent resin <NUM> is applied to surround the light-emitting devices <NUM>, in operations <NUM> and <NUM>. A method of surrounding the light-emitting devices <NUM> with the transparent resin <NUM> has been described above. A plurality of micro protrusions <NUM> may be formed in surfaces of transparent resins <NUM> corresponding to the light-emitting surfaces 50a of the light-emitting devices <NUM>.

Then, an opaque resin is applied to a rear surface of a transparent layer <NUM> to form an opaque molding layer <NUM>, in operations <NUM> and <NUM>. The transparent layer <NUM> may be formed with a size corresponding to the entire area of the substrates <NUM>. The transparent layer <NUM> may be formed of a transparent material, such as glass, transparent plastic, an optical film, or the like.

Then, the transparent layer <NUM> on which the opaque molding layer <NUM> is applied may be attached to the front surfaces of the substrates <NUM> on which the light-emitting devices <NUM> surrounded by the transparent resins <NUM> are mounted, in operations <NUM> and <NUM>. Accordingly, the opaque molding layer <NUM> covers partial surfaces of the plurality of transparent resins <NUM> and fills gaps between the plurality of transparent resins <NUM>.

The transparent layer <NUM> may planarize the opaque molding layer <NUM>. That is, when the rear surface of the transparent layer <NUM> is attached to the substrates <NUM>, a pressure may be applied to the opaque molding layer <NUM>, and accordingly, the opaque molding layer <NUM> may be planarized.

The opaque molding layer <NUM> surrounds the side surfaces of the transparent resins <NUM> corresponding to the respective side surfaces of the light-emitting devices <NUM>. Also, the opaque molding layer <NUM> may cover boundary lines or seams G between the substrates <NUM>. In this case, a height of the opaque molding layer <NUM> may be greater than or equal to a first height h1 and less than or equal to a second height h2 from installation surfaces <NUM> of the substrates <NUM>.

Also, a parting agent may be provided between the transparent layer <NUM> and the opaque molding layer <NUM>. After the opaque molding layer <NUM> is hardened, the transparent layer <NUM> may be removed, in operation <NUM>. When the transparent layer <NUM> is removed, a thickness of the display apparatus <NUM> may be reduced.

<FIG> is a view for describing a third method of manufacturing a display apparatus according to an embodiment.

Referring to <FIG>, a method of manufacturing the display apparatus <NUM> includes operation <NUM> of mounting a plurality of light-emitting devices <NUM> on a plurality of substrates <NUM> and arranging the substrates <NUM> to be adjacent to each other.

Then, a transparent resin <NUM> are applied to surround the light-emitting devices <NUM>, in operation <NUM>. A method of surrounding the light-emitting devices <NUM> with the transparent resin <NUM> has been described above. A plurality of micro protrusions <NUM> may be formed in surfaces of transparent resins <NUM> corresponding to light-emitting surfaces 50a of the light-emitting devices <NUM>.

Then, an opaque resin is applied on the front surfaces of the substrates <NUM> to form the opaque molding layer <NUM>, in operation <NUM>. Accordingly, the opaque molding layer <NUM> covers partial surfaces of the plurality of transparent resins <NUM> and fills gaps between the plurality of transparent resins <NUM>. The opaque resin may be applied, coated, or jetted on the substrates <NUM> through an opaque resin supplying apparatus. However, a method of forming the opaque molding layer <NUM> on the front surfaces of the substrates <NUM> is not limited to this.

Then, the opaque resin may be cut to planarize a front surface of the opaque molding layer <NUM>, in operation <NUM>. In contrast to the method shown in <FIG> and <FIG>, a blade may be used to planarize the opaque molding layer <NUM>. Because the method shown in <FIG> does not include a process of applying an opaque resin on the rear surface of a transparent layer <NUM> and attaching the transparent layer <NUM> to the plurality of substrates <NUM>, a process of manufacturing the display apparatus <NUM> may be simplified.

Through the above-described process, the opaque molding layer <NUM> surrounds the side surfaces of the plurality of transparent resins <NUM> corresponding to the respective side surfaces of the plurality of light-emitting devices <NUM>. Also, the transparent molding layers <NUM> may cover the boundary lines or seams G between the substrates <NUM>. A height of the opaque molding layer <NUM> may be greater than or equal to a first height or less than or equal to a second height from the installation surfaces <NUM> of the substrates <NUM>.

As described above, in the display module, the display apparatus, and the manufacturing method of the display apparatus, according to the embodiments, the plurality of light-emitting devices mounted on the substrates may be physically protected, and the picture quality of the display apparatus may be improved due to an improvement of optical performance.

Claim 1:
A display apparatus (<NUM>) comprising:
a plurality of substrates (<NUM>);
a plurality of light-emitting devices (<NUM>) mounted on the plurality of substrates (<NUM>);
a plurality of transparent resins (<NUM>) surrounding upper surfaces and side surfaces of the plurality of light-emitting devices (<NUM>), the plurality of transparent resins not covering lower surfaces of the light emitting devices;
a frame (<NUM>, <NUM>) supporting the plurality of substrates (<NUM>); and
an opaque molding layer (<NUM>) that is disposed on the plurality of substrates (<NUM>) between the plurality of transparent resins (<NUM>) and covers partial surfaces of the plurality of transparent resins (<NUM>),
wherein the opaque molding layer (<NUM>) covers a portion of a top surface of each of the plurality of transparent resins (<NUM>), and does not cover areas of the plurality of transparent resins (<NUM>) corresponding to light-emitting surfaces (50a) of the plurality of light-emitting devices (<NUM>), wherein the light-emitting surfaces (50a) are the upper surfaces of the light-emitting devices (<NUM>).