Patent Description:
LED displays constitute a display screen using a plurality of display modules disposed with a plurality of LEDs, and is widely used in indoor and outdoor large scale billboards and large scale electronic display board markets. Further, LED displays may be implemented as high quality large scale screens with superior brightness and color compared to previous LCD displays.

The LED displays are disadvantageous in that durability is decreased as a result of damage being generated by damage from the environment (e.g., moisture, ultraviolet rays, etc.) of being exposed outside or damage from static generated from a hand or body of a user in the process of installation.

Accordingly, a coating solution for waterproofing each of the plurality of LEDs disposed on the LED display has been conventionally applied through a dispensing or spraying method. <CIT> discloses one such conventional method for molding lenses for individual LEDs of a lighting unit.

However, the conventional method has been problematic in that much coating time and coating solution is consumed when coating an entire surface of the LED display.

According to one or more embodiments, a method for molding a display module, includes: forming a cavity using a die plate of a first die and a plurality of side surface dies; filling the cavity with a coating material; fixing the display module to a second die using a coupling body disposed on a second surface of the display module, opposite of a first surface of the display module disposed with a plurality of LEDs; soaking the display module in the coating material filled in the cavity; curing the coating material; and separating the cured coating material of the display module from the die plate.

According to an embodiment, the method further includes cooling the coating material after curing the coating material.

According to an embodiment, the forming the cavity includes moving the plurality of side surface dies to contact the die plate.

According to an embodiment, the filling the cavity with the coating material includes injecting the coating material such that a height of the coating material is greater than a height of the plurality of LEDs disposed on the first surface.

According to an embodiment, the separating the cured coating material from the die plate includes separating the plurality of side surface dies from the die plate.

According to an embodiment, each of the plurality of side surface dies includes: a contact body configured to contact with the die plate; an actuator including an axis coupled with the contact body, the actuator configured to move the contact body; and a guide body provided on the first die and configured to guide the contact body by slidably-coupling with the contact body, wherein the contact body is configured to slidably move along the guide body.

According to an embodiment, the soaking the display module in the coating material includes soaking the display module in a direction of the first surface such that a side surface of the plurality of LEDs is covered with the coating material.

According to an embodiment, the coating material includes a heat-curable resin having a light-transmissivity.

According to an embodiment, the die plate includes a plurality of grooves formed in a shape corresponding to the plurality of LEDs at a position corresponding to the plurality of LEDs, and the soaking the display module in the coating material includes inserting the plurality of LEDs into the plurality of grooves, respectively.

According to an embodiment, the coating material includes: a first coating material filled in the plurality of grooves and having a first light transmittance; and a second coating material stacked on the first coating material, and having a second light transmittance lower than the first light transmittance.

According to one or more embodiments, a display module includes a substrate comprising: a first surface disposed with a plurality of LEDs; a second surface, opposite of the first surface, that is disposed with a plurality of chips connected to the plurality of LEDs and further disposed with a coupling body. The display module further includes a molding part covering the first surface and the plurality of LEDs, and having a shape corresponding to a shape of the plurality of LEDs.

According to an embodiment, the molding part includes: a first portion formed to surround the plurality of LEDs; and a second portion positioned on an upper part of the first surface that is not disposed with the plurality of LEDs, wherein the first portion and the second portion are formed integrally.

According to an embodiment, a thickness of the first portion is smaller than a thickness of the second portion.

According to an embodiment, a first light transmittance of the first portion is higher than a second light transmittance of the second portion.

According to an embodiment, the molding part includes a heat-curable resin having a light-transmissivity.

According to one or more embodiments, a method for forming a display module, includes soaking a first surface of a substrate in a coating material, the first surface disposed with a plurality of LEDs, and the substrate further including a second surface, opposite of the first surface, that is disposed with a plurality of chips connected to the plurality of LEDs and further disposed with a coupling body; and curing the coating material while the first surface of the substrate is soaked in the coating material, the cured coating material forming a molding part that covers the first surface and the plurality of LEDs, and has a shape corresponding to a shape of the plurality of LEDs.

According to an embodiment, the coating material includes a heat-curable resin having a light-transmissivity, and the curing the coating material includes heat curing the coating material.

To sufficiently understand configurations and effects of embodiments of the disclosure as set out in the claims, non-limiting example embodiments of the disclosure will be explained reference to the attached drawings. However, it is to be understood that the disclosure is not limited to the embodiments disclosed below, and that the embodiments may be implemented to various forms and various modifications may be applied thereto. The descriptions of non-limiting examples embodiments are provided to fully convey the scope of the disclosure to one of ordinary skill in the art to which the disclosure pertains. For convenience of description, elements in the attached drawings have been illustrated enlarged in size compared with the actual size, and a ratio of each element may be exaggerated or reduced.

It will be further understood that when an element is disclosed as "on" or "in contact with" another element, the element may be in direct contact with or connected to another element, or may have another element present therebetween. Alternatively, when an element is described as being "directly on" or "directly connected to" another element, it is to be understood that another element may not be present therebetween. Other expressions that describe the relationship between the elements such as, for example, "between. " and "directly between. ", should be interpreted the same.

The terms such as "first," "second," and so on may be used to describe a variety of elements, but the elements should not be limited by these terms. The terms may be used only for the purpose of distinguishing one element from another. For example, a first element may be designated as a second element without departing from the scope of the present disclosure, and similarly, the second element may also be designated as the first element.

A singular expression includes a plural expression, unless otherwise specified clearly in context. It is to be understood that the terms such as "comprise" or "include" may be used herein to designate a presence of a characteristic, number, step, operation, element, component, or a combination thereof, and not to preclude a presence or a possibility of adding one or more of other characteristics, numbers, steps, operations, elements, components or a combination thereof.

The terms used in the embodiments of the disclosure may be interpreted to have meanings generally understood to one of ordinary skill in the art unless otherwise defined.

Embodiments of the disclosure may relate to providing a method for molding a display module with improved manufacturing efficiency and contrast ratio.

A structure of a molding device <NUM> according to an embodiment may be described below with references to <FIG>.

<FIG> is a perspective diagram illustrating a molding device <NUM> according to an embodiment of the disclosure, <FIG> is an exploded perspective diagram illustrating a molding device <NUM> according to an embodiment of the disclosure, <FIG> is a cross-sectional diagram taken long line A-A of <FIG> , <FIG> is an enlarged diagram illustrating area B of <FIG>, <FIG> is a lower perspective diagram illustrating a second die <NUM> according to an embodiment of the disclosure, <FIG> is a lower exploded perspective diagram illustrating a second die <NUM> according to an embodiment of the disclosure, <FIG> is a perspective diagram illustrating a first die <NUM> according to an embodiment of the disclosure, <FIG> is an enlarged diagram illustrating area D of <FIG>, and <FIG> is an exploded perspective diagram illustrating a first side surface die <NUM>-<NUM> according to an embodiment of the disclosure.

The molding device <NUM> may be a device molding a display module disposed with a plurality of LEDs, and may include a first die <NUM> and a second die <NUM> coupled to be detachable from the first die <NUM>.

The die may be designating a press mold for manufacturing, and may be designated as a molding, a mold, a core, or an injection molding.

The first die <NUM> may be coupled with the second die <NUM> for molding the display module <NUM>, and may include a die plate <NUM> for forming an exterior of a molding part <NUM> (see <FIG>) of the display module <NUM>, a plurality of side surface dies <NUM> capable of selectively contacting with the die plate <NUM>, a heating line <NUM> (see <FIG>) capable of applying heat to the die plate <NUM>, and a cooling line <NUM> (see <FIG>) capable of cooling the die plate <NUM>.

The die plate <NUM> may form a cavity C to be filled with a coating material T for molding a display module <NUM> together with the plurality of side surface dies <NUM>.

Specifically, based on the plurality of side surface dies <NUM> contacting side surfaces of the die plate <NUM>, the cavity C, which is a space that the coating material T may be injected, may be formed.

The shape of display module <NUM> may be determined according to the die plate <NUM> and the shape of the plurality of side surface dies <NUM> contacting the die plate <NUM>.

For example, the shape of a front surface of the die plate <NUM> may correspond with the shape of an upper surface <NUM> of the molding part <NUM>, and the shape of the plurality of side surface dies <NUM> may correspond with the shape of a side surface <NUM> of the molding part <NUM>.

Specifically, based on the die plate <NUM> being formed flatly, the upper surface <NUM> of the molding part <NUM> may be formed flatly, and in case the die plate <NUM> has a shape of an uneven part, the uneven part may be formed on the upper surface of the molding part <NUM>.

In addition, a size of the die plate <NUM> may correspond with a size of a substrate <NUM>. Accordingly, even when the display module <NUM> formed with the molding part <NUM> on the substrate <NUM> is completed, a process of removing a separate molding part to fit the size of the substrate <NUM> may not be needed.

In addition, the first die <NUM> may include a first die contact surface <NUM> capable of contacting with a second die contact surface <NUM> of the second die <NUM>. The first die contact surface <NUM> may have a shape complementing the second die contact surface <NUM>.

In addition, in case the first die contact surface <NUM> and the second die contact surface <NUM> are in contact, an inner space of a molding device <NUM> including the die plate <NUM> may be sealed from the outside.

The inner space of the molding device <NUM> may refer to a space including the cavity C containing the coating material T.

Accordingly, in case a vacuum flow path (not shown) for vacuuming the inner space of the molding device <NUM> is formed, the inner space of the molding device <NUM> may be vacuumed when the first die <NUM> and the second die <NUM> are in contact.

In addition, referring to <FIG>, the first die contact surface <NUM> may be formed with a sealing or a sealing groove <NUM> for inserting an O-ring. Accordingly, when the first die <NUM> and the second die <NUM> are in contact, the inner space of the molding device <NUM> may be completely sealed from the outside.

The plurality of side surface dies <NUM> are provided on the first die <NUM>, and provided to selectively contact the side surfaces of the die plate <NUM>. The specific structure of the plurality of side surface dies <NUM> may be described hereafter with reference to <FIG>.

Referring to <FIG>, the display module <NUM> includes a first surface <NUM>-<NUM> disposed with a plurality of LEDs P, a plurality of chips <NUM> to be opposite to the first surface <NUM>-<NUM> and electrically connected with the plurality of LEDs P, and a substrate <NUM> including a second surface <NUM>-<NUM> disposed with a coupling member <NUM>. The coupling member <NUM> includes at least one coupling body.

The plurality of LEDs P may be, as self-light emitting display elements, inorganic light emitting elements that emits light on its own, and disposed at a pre-set distance on the substrate <NUM>.

The plurality of LEDs P may operate as one pixel, and the one pixel may include a red light emitting diode (LED) emitting a red light, a green LED emitting green light, and a blue LED emitting a blue light. In addition, the one pixel may further include a white LED in addition to the red (R)/green (G)/ blue (B) LED.

Accordingly, one pixel may realize various colors through the combination of red LED, green LED, and blue LED.

Although, the plurality of LEDs of one display module has been described above as constituting one pixel, the plurality of LEDs may constitute a plurality of pixels in the embodiment.

In addition, in case the display module <NUM> is fixed to the second die <NUM>, the first surface <NUM>-<NUM> disposed with the plurality of LEDs P may be disposed to face the die plate <NUM> of the first die <NUM>.

The plurality of chips <NUM> may be disposed on the second surface <NUM>-<NUM> of the substrate <NUM>, and may control the plurality of LEDs P. For example, the plurality of chips <NUM> may include various semiconductor chips such as a processor and a transistor, and provide a control signal and/or power to the plurality of LEDs P through wiring formed on the substrate <NUM>.

In addition, the coupling member <NUM> may be disposed on the second surface <NUM>-<NUM> of the substrate <NUM>. For example, the coupling member <NUM> may be configured in plurality, and disposed uniformly (or dispersingly) at a peripheral area of the substrate <NUM> to stably fix the display module <NUM> to the second die <NUM>.

In addition, the coupling member <NUM> may be composed of a metal, and disposed to protrude from the second surface <NUM>-<NUM>. Accordingly, because the coupling member <NUM> may be coupled to the second die <NUM>, the display module <NUM> may be stably fixed to the second die <NUM>.

Thus, the display module <NUM> may be conveniently detachable from the second die <NUM>, and the molding efficiency of the display module <NUM> may be improved.

In addition, the coupling member <NUM> may fix the display module <NUM> to the second die <NUM> when molding the display module <NUM>, and the display module <NUM> with the molding completed may be fixed to a tiling plate (not shown).

Accordingly, because the coupling member <NUM> may be used for fixing the molding of the display module <NUM>, and fixing to constitute a display screen, the manufacturing efficiency of a display device using the display module <NUM> may be improved.

Referring to <FIG> and <FIG>, the second die <NUM> may be positioned on the upper part of the first die <NUM>, and may move vertically relative to the first die <NUM>. The second die <NUM> may include the second die contact surface <NUM> contacting the first die contact surface <NUM> of the first die <NUM>, a first sealing member <NUM> sealing the inner space of the molding device <NUM> by contacting with the plurality of side surface dies <NUM>, and a fixing member <NUM> for fixing the display module <NUM>. The first sealing member <NUM> may include at least one sealing body, and the fixing member <NUM> may include at least one fixing body.

The first sealing member <NUM> may be disposed around the fixing member <NUM>, and may seal the inner space of the molding device <NUM> by contacting with a contact member <NUM> of the plurality of side surface dies <NUM> installed in the first die <NUM> (see <FIG>). The contact member <NUM> may include at least one contact body.

The first sealing member <NUM> may be composed of rubber with elastic force, and fixed to the second die <NUM>.

Referring to <FIG> and <FIG>, the fixing member <NUM> may be configured to fix the display module <NUM>, and may be inserted in the second die <NUM>.

The fixing member <NUM> may include a coupling hole <NUM> to which the coupling member <NUM> may be inserted, a receiving hole <NUM> formed in the shape of the plurality of chips <NUM>, and a magnetic material <NUM> for fixing the coupling member <NUM>.

The coupling hole <NUM> may correspond to the number of the coupling member <NUM>, and may be formed at a position corresponding to a position where the coupling member <NUM> is protrudingly disposed. Accordingly, when the coupling member <NUM> is inserted into the coupling hole <NUM>, the coupling member <NUM> may be fixed into the coupling hole <NUM> by the magnetic material <NUM> disposed adjacently to the coupling hole <NUM>.

Thus, because the display module <NUM> is conveniently detachable to the second die <NUM>, the molding efficiency of the display module <NUM> may be improved.

In the case the magnetic material <NUM> is not provided, the coupling member <NUM> may be fitted-coupled to the coupling hole <NUM>, or thread-coupled.

The receiving hole <NUM>, as a space for containing the plurality of chips <NUM>, may be a shape corresponding to the position and shape of the pre-set plurality of chips <NUM>.

Accordingly, even when the second die <NUM> is in contact relative to the first die <NUM> when the display module <NUM> is fixed to the second die <NUM>, because the fixing member <NUM> receives pressure, the plurality of chips <NUM> inserted into the receiving hole <NUM> may be prevented from becoming damaged.

The shape of the receiving hole <NUM> may be varied, and the fixing member <NUM> may also be changed according to the display module <NUM> for molding.

As illustrated in <FIG>, the plurality of side surface dies <NUM> may be configured in plurality. For example, the plurality of side surface dies <NUM> may include a first side surface die to a fourth side surface die <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>.

However, for convenience of description, <FIG> is described based on the first side surface die <NUM>-<NUM>, but the configuration of the first side surface die <NUM>-<NUM> is the same as the configurations of the second side surface to the fourth side surface die <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>.

The first side surface die <NUM>-<NUM> may include the contact member <NUM> contacting the die plate <NUM>, and an actuator <NUM> axis-coupled with the contact member <NUM> and may move the contact member <NUM>.

The contact member <NUM> may be in selective contact with the side surfaces of the die plate <NUM> to form cavity C together with the die plate <NUM>. In addition, the contact member <NUM> may include a second sealing member <NUM> directly contacting the die plate <NUM>, and a connecting member <NUM> connecting the second sealing member <NUM> with an axis <NUM> of the actuator <NUM>.

The second sealing member <NUM> may form the cavity C together with the die plate <NUM>, and may seal a side surface of the cavity so that the coating material T filling the cavity C does not leak.

For example, the second sealing member <NUM> may be formed of a rubber with elastic force. The second sealing member <NUM> may include at least one sealing body.

In addition, in the case the second sealing member <NUM> may be fixed to the connecting member <NUM>, a first contact surface 32a of the second sealing member <NUM> and a second contact surface 33a of the connecting member <NUM> may form one flat surface.

Accordingly, the first contact surface 32a and the second contact surface 33a may contact the die plate <NUM> to form the cavity C and simultaneously seal the side surface of the cavity C so that the coating material T filling the cavity C does not leak.

The connecting member <NUM> may include a seating part 33b that seats and fixes the second sealing member <NUM>, a coupling groove 33c that receives and fixes the axis <NUM>, and a guide slot 33d that guides the movement of the contact member <NUM> and is formed on both side surfaces.

The coupling groove 33c may be configured to a shape for the actuator <NUM> to insert and fix one end of the axis <NUM>, and may move the contact member <NUM> along the movement of the axis <NUM>.

The guide slot 33d may receive a guide protruding part 52a of the guide member <NUM> as illustrated in <FIG>, and move along the guide protruding part 52a. The guide member <NUM> may include at least one guide body.

Accordingly, even if the contact member <NUM> receives power by the axis <NUM>, the contact member <NUM> may not be inclined toward one side and may be guided to have stable movement by connection with the guide member <NUM>.

The guide member <NUM> may be provided on the first die <NUM> and may be slidably-coupled with the contact member <NUM> to guide the contact member <NUM>. Specifically, a respective one of the guide member <NUM> may be disposed on each of the both sides of the side surface dies <NUM> and may guide the side surface dies <NUM>.

For example, the guide protruding part 52a may be formed on one side of the guide member <NUM>, and the guide protruding part 52a may be inserted into the guide slot 33d of the contact member <NUM> and the contact member <NUM> may be moved.

The actuator <NUM> may have a configuration for controlling power to the first side surface die <NUM>, and may be formed in various configurations such as a motor. The actuator <NUM> may be disposed on each of the side surfaces of the first die <NUM>.

For example, a coupling surface 35a of the actuator <NUM> may be fixed to the side surface of the first die <NUM>.

The process of forming the cavity C according to an embodiment will be described below with references to <FIG>.

<FIG> is an upper surface diagram illustrating a state in which a die plate <NUM> and a plurality of side surface dies <NUM> are spaced apart according to an embodiment of the disclosure, and <FIG> is an upper surface diagram illustrating a state in which a die plate <NUM> and a plurality of side surface dies <NUM> are in contact according to an embodiment of the disclosure.

First, as illustrated in <FIG>, a first side surface die to a fourth side surface die <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> may be in a first state of being spaced apart at predetermined intervals with the die plate <NUM>.

Specifically, the contact member of each of the first side surface die to the fourth side surface die <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> may be in a state of being spaced apart with the die plate <NUM>. That is, the cavity C may not be in a formed state in the first state.

Next, as illustrated in <FIG>, the first side surface die to the fourth side surface die <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> may be moved to be in contact with the die plate <NUM>.

Specifically, the actuator <NUM> of each of the first side surface die to the fourth side surface die <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> may move the contact member <NUM> through the axis <NUM>. Accordingly, the contact member <NUM> may contact the die plate <NUM> by being guided by the guide member <NUM>.

That is, as illustrated in <FIG>, the first side surface die to the fourth side surface die <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> may be in a second state of being in contact with the die plate <NUM>.

Based on the contact member <NUM> contacting the die plate <NUM>, the contact member <NUM> and the die plate <NUM> may then form the cavity C, which is a space for the coating material T to be filled.

That is, the cavity C may be formed as the plurality of side surface dies <NUM> are moved to contact the die plate <NUM>.

For example, the cavity C may refer to a rectangular parallelepiped space due to the shape of the contact member <NUM> and the die plate <NUM>.

A method for molding a display module <NUM> according to an embodiment may be described in greater detail below with references to <FIG> and <FIG>.

<FIG> is a cross-sectional diagram illustrating a state in which a die plate <NUM> and a plurality of side surface dies <NUM> form a cavity C according to an embodiment of the disclosure, <FIG> is a cross-sectional diagram illustrating a state in which a cavity C is filled with coating material T according to an embodiment of the disclosure, <FIG> is an enlarged diagram illustrating area E of <FIG>, <FIG> is a cross-sectional diagram illustrating a state in which a first die <NUM> and a second die <NUM> are coupled according to an embodiment of the disclosure, <FIG> is an enlarged diagram illustrating area F of <FIG>, <FIG> is a cross-sectional diagram illustrating a state in which a plurality of side surface dies <NUM> has moved in the state illustrated in <FIG>, <FIG> is a cross-sectional diagram illustrating a state in which a first die <NUM> and a second die <NUM> are spaced apart according to an embodiment of the disclosure, and <FIG> is a flowchart illustrating a method for molding a display module <NUM> according to an embodiment of the disclosure.

First, as illustrated in <FIG>, the cavity C may be formed using the die plate <NUM> of the first die <NUM> and the plurality of side surface dies <NUM> (S10).

Specifically, the contact member <NUM> of the plurality of side surface dies <NUM> may contact the side surface of the die plate <NUM> to form the cavity C, which is a space in which the coating material T may be injected.

Next, as illustrated in <FIG>, the coating material T may be filled in the formed cavity C (S20).

The coating material T may include a heat-curable resin having a light-transmissivity. Accordingly, the coating material T may be in a state of having a predetermined viscosity at room temperature, and when heat is applied to the coating material T, the coating material T may be cured.

In addition, the coating material may include a binder resin, a photopolymerization initiator, a black pigment and a solvent, or may be comprised of a resin composition including black pigment for shielding.

Accordingly, because the coating material T constitutes the plurality of LEDs P and the molding part <NUM> that covers the substrate disposed with the plurality of LEDs P, the outside light introduced to the display module <NUM> may be absorbed while simultaneously improving contrast ratio, and by protecting the plurality of LEDs P, the plurality of LEDs P may be prevented from being damaged by moisture, static, and the like.

In addition, the coating material T may be formed to a first height H1 on the die plate <NUM>. The first height H1 may be higher than a second height H2 of the plurality of LEDs P covering all of the upper surface and the side surfaces of the plurality of LEDs P.

That is, in the operation of injecting the coating material to the cavity (S20), the coating material T may be injected to be higher than the height of the plurality of LEDs P disposed on the first surface <NUM>-<NUM> of the display module <NUM>.

Next, the display module <NUM> may be fixed to the second die <NUM> (S30). The display module <NUM> may be in a state in which the plurality of LEDs P is disposed on the first surface <NUM>-<NUM> of the substrate <NUM>, and the plurality of chips <NUM> is disposed on the second surface <NUM>-<NUM>.

Specifically, the display module <NUM> may be fixed to the second die <NUM> through the coupling member <NUM> disposed on the second surface <NUM>-<NUM> opposite to the first surface <NUM>-<NUM> disposed with the plurality of LEDs P.

For example, because the coupling member <NUM> formed on the second surface <NUM>-<NUM> is inserted into the coupling hole <NUM> formed on the fixing member <NUM> of the second die <NUM>, the display module <NUM> may be fixed to the second die <NUM>.

Because the plurality of chips <NUM> is inserted into the receiving hole <NUM> which is formed to the shape of the plurality of chips <NUM> on the fixing member <NUM>, damage to the plurality of chips <NUM> may be prevented even when being downward pressed as the second die <NUM> and the first die <NUM> are in contact.

As illustrated in <FIG>, the display module <NUM> may then be soaked in the coating material T (S40). Specifically, the second die <NUM> may, when the display module <NUM> is in a fixed state, be moved to be in contact with the first die <NUM>.

The second die <NUM> may be moved until the coating material T filled in the cavity C covers all of the first surface <NUM>-<NUM> and the plurality of LEDs P. That is, the first surface <NUM>-<NUM> may contact the coating material T until the side surfaces of the plurality of LEDs P are covered.

For example, the second die <NUM> may move toward the first die <NUM> so that a sum of the second height H2 of the plurality of LEDs P and the third height H3 of the coating material T on the plurality of LEDs P is the same as the first height H1 at which the coating material T is in contact with the first surface <NUM>-<NUM>.

In addition, when the first die <NUM> and the second die <NUM> are in contact, the cavity C may be sealed from the outside, and when a vacuum line (not shown) is formed on the molding device <NUM>, the inside may become vacuumed.

Accordingly, as the air bubbles within the coating material T are released to the outside by vacuuming, air bubbles being present inside the molding part <NUM> may be prevented. Thus, light emitted from the plurality of LEDs P may be prevented from diffusing or refracting due to the air bubbles, and a uniform brightness of the display screen may be realized.

Next, as illustrated in <FIG>, the coating material T may be cured as the display module <NUM> is in a soaked state in the coating material T (S50). Specifically, the coating material T may receive heat from a heating line <NUM> provided in the first die <NUM> thereby rising in temperature, and the heat-curable coating material T may be cured.

The heating line <NUM> may be sufficient if provided on the first die <NUM> to apply heat to the coating material T, and the method of heating may be varied. In addition, the heating line <NUM> may not be limited to being formed on the first die <NUM>, but may also be formed on the second die <NUM>.

Accordingly, based on applying heat to the coating material T, the coating material T may be cured when the plurality of LEDs P and the first surface <NUM>-<NUM> of the display module <NUM> is covered and may form the molding part <NUM>.

The molding part <NUM> that is cured may then be cooled through a cooling line <NUM> provided in the second die <NUM> thereby lowering in temperature. That is, after the coating material T is cured, the coating material T may be cooled. The cooling line <NUM> may be sufficient if provided on the first die <NUM> to cool the molding part <NUM>, and the method of cooling may be varied.

In addition, the cooling line <NUM> may not be limited to being formed on the first die <NUM>, but may also be formed on the second die <NUM>. In addition, the heating line <NUM> and the cooling line <NUM> may be formed with the same line, and the heating or cooling may be selectively performed according to the temperature of the fluid flowing in the corresponding line.

Accordingly, by cooling the molding part <NUM> that is at a high temperature, separating the molding part <NUM> from the die plate <NUM> and the plurality of side surface dies <NUM> may be easily performed.

Next, as illustrated in <FIG>, the coating material T of the display module <NUM> that is cured may be separated from the die plate <NUM> (S60).

First, as illustrated in <FIG>, the plurality of side surface dies <NUM> may be spaced apart from the die plate <NUM>. Specifically, the contact member <NUM> of the plurality of side surface dies <NUM> may be spaced apart from the side surface <NUM> of the molding part <NUM>.

Next, as illustrated in <FIG>, the second die <NUM> may move relative to the first die <NUM>, and the molding part <NUM> may be separated from the die plate <NUM>. Specifically, the upper surface <NUM> of the molding part <NUM> may be separated from the die plate <NUM>.

Accordingly, the molding part <NUM> may be separated from the die plate <NUM> and the plurality of side surface dies <NUM>.

Thus, by forming the molding part <NUM> through the mold method, time required for forming the molding part <NUM> may be significantly reduced, and since the coating material T is a quantitative amount filling the cavity C, the amount of coating material T may also be reduced, thereby improving the manufacturing efficiency of the display module <NUM> significantly.

A structure of the display module <NUM> constructed through the method for molding the display module illustrated in <FIG> may be described below.

<FIG> is a cross-sectional diagram illustrating a display module <NUM> according to an embodiment of the disclosure.

The display module <NUM> may cover the first surface <NUM>-<NUM> and the plurality of LEDs P, and may include the molding part <NUM> with the shape corresponding to the shape of the plurality of LEDs P.

The upper surface of the molding part <NUM> may be formed flatly. Accordingly, as the light emitted from the plurality of LEDs P is not refracted by the molding part <NUM>, a uniform brightness of the display screen may be realized.

In addition, the molding part may be composed of a material that absorbs outside light, and by absorbing the outside light, the contrast ratio of the display screen may be improved.

Further, by forming the molding part <NUM> that is cured and covers the plurality of LEDs P and the first surface <NUM>-<NUM> on the substrate <NUM> disposed with the plurality of LEDs P, the plurality of LEDs P may be protected from outside moisture, static and the like, and the lifespan of the display module <NUM> may be improved.

A molding device <NUM>' and a display module <NUM>' manufactured by the molding device <NUM>' according to a modified embodiment may be described below with references to <FIG>.

<FIG> is a cross-sectional view illustrating a molding device <NUM>' according to a modified embodiment of the disclosure, <FIG> is an enlarged diagram illustrating area G of <FIG>, and <FIG> is a cross-sectional diagram illustrating a display module <NUM>' according to a modified embodiment of the disclosure.

Hereinbelow, like reference numerals have been used for like configurations, and overlapping descriptions have been omitted. For example, the first die <NUM>, the second die <NUM>, the plurality of side surface dies <NUM>, and the fixing member <NUM> are the same as described above, and overlapping descriptions have been omitted.

The die plate <NUM>' may include a plurality of grooves <NUM>-<NUM> formed to a shape corresponding to the plurality of LEDs P at the position corresponding to the plurality of LEDs P. Accordingly, the operation of soaking a display module <NUM>' in the coating material T may further include an operation of inserting the plurality of LEDs P respectively into the plurality of grooves <NUM>-<NUM>.

Specifically, as illustrated in <FIG>, the die plate <NUM>' may include the plurality of grooves <NUM>-<NUM> and a protruding part <NUM>-<NUM> formed between the plurality of grooves.

Accordingly, by filling the die plate <NUM>' with coating material T having viscosity, a molding part <NUM>' with a first portion <NUM>'-<NUM> and a second portion <NUM>'-<NUM> may be formed by the plurality of grooves <NUM>-<NUM> and the protruding part <NUM>-<NUM>.

Specifically, the molding part <NUM>' may include a first portion <NUM>'-<NUM> protrudingly formed to surround the plurality of LEDs P and a second portion <NUM>'-<NUM> positioned on the upper part of the first surface <NUM>-<NUM> not disposed with the plurality of LEDs P.

The first portion <NUM>'-<NUM> may be formed by the plurality of grooves <NUM>-<NUM>, and the second portion <NUM>'-<NUM> may be formed by the protruding part <NUM>-<NUM>. That is, the first portion <NUM>'-<NUM> and the second portion <NUM>'-<NUM> may be a shape complementary to the die plate <NUM>' including the plurality of grooves <NUM>-<NUM> and the protruding part <NUM>-<NUM>.

Further, the first portion <NUM>'-<NUM> and the second portion <NUM>'-<NUM> may be formed integrally with the same material.

In addition, the shape of the plurality of grooves <NUM>-<NUM> may be a rectangular parallelepiped shape. That is the die plate <NUM>' may include a surface with a uneven part pattern, which is the rectangular parallelepiped shape.

Accordingly, as illustrated in <FIG>, a first display module <NUM>'-<NUM> and a second display module <NUM>'-<NUM> including the molding part <NUM>' formed by the die plate <NUM>' including the plurality of grooves <NUM>-<NUM> and the protruding part <NUM>-<NUM> may be disposed side by side.

The gap in the first portion <NUM>'-<NUM> may include a pre-set spacing distance L. The spacing distance L may correspond with the widthwise length of the protruding part <NUM>-<NUM>.

The distance between the gap of the first portion <NUM>'-<NUM> disposed on the edge of the second display module <NUM>'-<NUM> adjacent with the first portion <NUM>'-<NUM> disposed on the edge of a first display module <NUM>'-<NUM> may be the same as the pre-set spacing distance L.

That is, in case the display modules formed with the molding part <NUM>' including the first portion <NUM>'-<NUM> and the second portion <NUM>'-<NUM> are arranged side by side to form a large scale screen, the distance of the gaps of the first portion <NUM>'-<NUM> may all satisfy the pre-set spacing distances L.

Accordingly, even when viewing a screen implemented by the plurality of display modules, a user may not recognize a seam between the plurality of display modules due to the pattern with all of the same spacing distances L.

In addition, because the molding part <NUM>' absorbs outside light by being composed of a material that absorbs outside light, a seamless screen configured by the plurality of display modules may be realized.

According to another embodiment, the first portion <NUM>'-<NUM> and the second portion <NUM>'-<NUM> may be composed of materials different from each other. Specifically, a first light transmittance of the first portion <NUM>'-<NUM> may be higher than a second light transmittance of the second portion <NUM>'-<NUM>.

That is, the coating material T may be filled in the plurality of grooves <NUM>-<NUM>, and may include a first coating material with the first light transmittance and a second coating material stacked on the first coating material with the second light transmittance, which is lower than the first light transmittance.

Specifically, the first coating material with the first light transmittance may be first injected in the plurality of grooves <NUM>-<NUM>, and by stacking the second coating material with the second light transmittance on the upper part of the first coating material, the coating material T may be formed.

The first light transmittance of the first portion <NUM>'-<NUM> may then be higher than the second light transmittance of the second portion <NUM>'-<NUM> through the method for molding the display module according to <FIG>.

The coating material T including the black pigment may absorb outside light better the lower the light transmittance.

Thus, the first portion <NUM>'-<NUM> surrounding the plurality of LEDs P may realize a display screen without loss of light emitting from the plurality of LEDs P due to the first portion <NUM>'-<NUM> with high light transmittance.

Simultaneously, because the second portion <NUM>'-<NUM> of an area not disposed with the plurality of LEDs P may absorb outside light better compared to the first portion <NUM>'-<NUM>, the gap of the plurality of LEDs P may be configured to not be visible externally.

Further, considering that the plurality of display modules may be arranged to implement a large scale display screen, a predetermined brightness or more of the plurality of LEDs P concurrently with a seamless display may be realized.

A molding device <NUM>" and a display module <NUM>" manufactured by the molding device <NUM>" according to another modified embodiment will be described below.

<FIG> is a cross-sectional diagram illustrating a molding device <NUM>" according to another modified embodiment of the disclosure, <FIG> is an enlarged diagram illustrating area H of <FIG>, and <FIG> is a cross-sectional diagram illustrating a display module <NUM>" according to another modified embodiment of the disclosure.

A thickness of a first portion <NUM>"-<NUM> may be smaller than a thickness of a second portion <NUM>"-<NUM> on a die plate <NUM>".

For example, as illustrated in <FIG>, a sixth height H6 corresponding to the thickness of the first portion <NUM>"-<NUM> may be smaller than a seventh height H7 corresponding to the thickness of the second portion <NUM>"-<NUM>.

That is, the sixth height H6 may refer to the length from the upper surface of the plurality of LEDs P to an upper surface <NUM>"-<NUM> of the plurality of grooves, and the seventh height H7 may refer to the length from the first surface <NUM>-<NUM> of the substrate <NUM> to an upper surface <NUM>"-<NUM> of the protruding part.

Further, the sixth height H6 may be smaller than a fifth height H5 of the first portion <NUM>'-<NUM> illustrated in <FIG>, and the seventh height H7 may be smaller than an eighth height H8 of the second portion <NUM>'-<NUM> illustrated in <FIG>.

Accordingly, as illustrated in <FIG>, because the sixth height H6 of the first portion <NUM>"-<NUM> is smaller than the eighth height H8 of the second portion <NUM>"-<NUM>, the light transmittance of the first portion <NUM>"-<NUM> may be better than the light transmittance of the second portion <NUM>"-<NUM>, and an outside light absorption rate of the first portion <NUM>"-<NUM> may be smaller than an outside light absorption rate of the second portion <NUM>"-<NUM>.

Accordingly, the first portion <NUM>"-<NUM> surrounding the plurality of LEDs P may realize a display screen without loss of light emitting from the plurality of LEDs P due to the first portion <NUM>"-<NUM> with high light transmittance.

Simultaneously, because the second portion <NUM>"-<NUM> of an area not disposed with the plurality of LEDs P may absorb outside light better compared to the first portion <NUM>"-<NUM>, the gap of the plurality of LEDs P may be configured to not be visible externally.

According to another embodiment, if one of the plurality of LEDs P of the display module <NUM> is faulty, an exchange of the faulty LED may also be performed through the molding method.

For example, based on one LED of the display module <NUM> being faulty, the corresponding LED and the molding part <NUM> adjacent to the LED may be removed. The method for removing the molding part <NUM> such as physical removal method and chemical removal method may be varied according to necessity.

A new LED may then be disposed on the substrate <NUM> to the position corresponding to the faulty LED. The disposing the new LED on the substrate <NUM> may include connecting the gap between the new LED and the substrate <NUM> electrically and physically.

Next, a coating material is filled into an empty space of the molding part <NUM>, that is removed, adjacent to the corresponding LED, and the corresponding portion may be cured by pressing and heating through a die.

In addition, a unit molding part of one unit adjacent to one LED may be manufactured in plurality through the molding method, and the corresponding manufactured unit molding part may be inserted and fixed in the empty space of the molding part <NUM>, that is removed, adjacent to the corresponding LED.

The unit molding part may be a shape corresponding to the first portion <NUM>-<NUM> surrounding to one LED.

In the above, various embodiments of the disclosure have been described respectively and individually, but each embodiment may not necessarily be implemented on its own, and the configuration and operations of each embodiments may be implemented in combination with at least one other embodiment.

Claim 1:
A method for molding a display module (<NUM>), the method comprising:
forming a cavity (C) using a die plate (<NUM>) of a first die (<NUM>) and a plurality of side surface dies (<NUM>);
filling the cavity (C) with a coating material (T);
fixing a display module (<NUM>) to a second die (<NUM>) using a coupling body disposed on a second surface (<NUM>-<NUM>) of the display module (<NUM>), opposite of a first surface (<NUM>-<NUM>) of the display module (<NUM>) disposed with a plurality of LEDs (P);
soaking the display module (<NUM>) in the coating material (T) filled in the cavity (C);
curing the coating material (T); and
separating the cured coating material (T) of the display module (<NUM>) from the die plate (<NUM>).