Display device and method of manufacturing the same

Abstract

A method for manufacturing a display device including a plurality of modular displays, the method comprising: arranging a plurality of modular displays on a rack, each of the plurality of modular displays comprising a corresponding plurality of pixels having a red inorganic light-emitting element, a green inorganic light-emitting element, and a blue inorganic light-emitting element; forming a film on the plurality of modular displays; and forming a covering between the light-emitting elements of the plurality of modular displays by removing areas of the film corresponding to the light-emitting elements of the plurality of modular displays.

Description

Technical Field

[0001] The present disclosure relates to a display device and a manufacturing method thereof, and more particularly, to a display device composed of a plurality of modular displays and a manufacturing method thereof. Background Art

[0002] The latest development of electronic technology has used LEDs (light emitting diodes) for the development of various display devices. Recently, the demand for large-screen display devices has been growing, and more and more resources are being used to develop display devices with large screens of 100 inches or more.

[0003] In the case of directly manufacturing a large-screen display device in a conventional manner of a liquid crystal display (LCD) or an organic light-emitting diode (OLED), it is difficult to mass-produce due to problems such as yield reduction that occur in a cell process and a thin film transistor (TFT) deposition process.

[0004] When a large-screen display device is manufactured by modularizing a small-screen display device and then attaching multiple modular displays in series, it has the advantages of being able to solve the problem of reduced yield that occurs when directly manufacturing a large-screen display device and being able to customize the screen size according to customer needs.

[0005] However, in the case of assembling multiple modular displays, there is a problem that a seam area is formed between the multiple modular displays, and due to the difference in optical density and refractive index, the user cannot recognize the display device as a whole screen and may feel that the display device looks unnatural.

[0006] When a filling material is applied to a joint region having the same optical density and refractive index as those of a modular display, position tolerance gradually accumulates according to the number of times a plurality of modular displays are arranged, and therefore, the material cannot be uniformly filled into the joint region. Therefore, there is a problem of increased visibility of the joint region due to the difference in refractive index and optical density with the modular display. Summary of the invention

[0007] Technical issues

[0008] A display device and a method for manufacturing the same are provided. The display device covers a seam area formed when a plurality of modular displays are arranged so that a user cannot recognize the seam area.

[0009] Technical solutions for solving technical problems

[0010] According to one aspect of the present disclosure, a method for manufacturing a display device including a plurality of modular displays is provided, the method including: arranging a plurality of modular displays on a rack, each of the plurality of modular displays including a corresponding plurality of pixels having a red inorganic light-emitting element, a green inorganic light-emitting element, and a blue inorganic light-emitting element; forming a film on the plurality of modular displays; and forming a covering between the light-emitting elements of the plurality of modular displays by removing areas of the film corresponding to the light-emitting elements of the plurality of modular displays.

[0011] Forming the cover may include forming the cover on edges of adjacent modular displays of the plurality of modular displays.

[0012] Forming the cover may include: irradiating portions of the film corresponding to edges of adjacent modular displays with a laser; and removing areas of the film other than the irradiated portions of the film.

[0013] The method may further include inspecting by optical inspection a portion of the film corresponding to a seam area formed between adjacent modular displays.

[0014] The cover may cover a seam area formed between adjacent modular displays and fill at least a portion of the seam area.

[0015] The film may include a base film and a transfer film attached to the base film, and forming the film may include laminating the film on the plurality of modular displays such that the transfer film is disposed to face the plurality of modular displays.

[0016] Forming the cover may include forming the cover by removing areas of the base film and the transfer film that are not irradiated with the laser.

[0017] The thickness of the transfer film may be based on the heights of the red inorganic light emitting elements, the green inorganic light emitting elements, and the blue inorganic light emitting elements included in the plurality of pixels.

[0018] Forming the cover may include forming the cover between the light emitting elements of each modular display.

[0019] According to one aspect of the present disclosure, a display device is provided, comprising: a frame; a plurality of modular displays arranged on the frame so that a seam area is formed between adjacent modular displays among the plurality of modular displays; and a processor configured to control the plurality of modular displays to display an image, wherein each of the plurality of modular displays comprises: a substrate; and a plurality of pixels on the substrate, respectively comprising a red inorganic light-emitting element, a green inorganic light-emitting element, and a blue inorganic light-emitting element; and a cover covering the seam area and attached to corresponding edges of adjacent modular displays that define the seam area.

[0020] The cover may fill at least a portion of the seam area between respective edges of adjacent modular displays.

[0021] The cover may include a transfer film that has been irradiated with a laser to attach the transfer film to corresponding edges of defined seam areas of adjacent modular displays, and the transfer film may have a predetermined thickness depending on the heights of the red inorganic light-emitting elements, green inorganic light-emitting elements, and blue inorganic light-emitting elements included in the plurality of pixels.

[0022] The width of the overlay may be less than a distance between adjacent pixels in the plurality of pixels and may be greater than a distance between adjacent modular displays in the plurality of modular displays. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The above and other aspects, features and advantages of certain embodiments of the present disclosure will become more apparent through the following description in conjunction with the accompanying drawings, in which:

[0024] Figure 1 is a diagram of a display device according to an embodiment;

[0025] Figure 2 is a flow chart of a method for manufacturing a display device according to an embodiment;

[0026] Figure 3A , Figure 3B , Figure 4A , Figure 4B , Figure 5A , Figure 5B , Figure 6 , Fig. 7A and Figure 7B is a diagram showing a method for manufacturing a display device according to an embodiment;

[0027] Figure 8 is a diagram showing another method of manufacturing a display device according to an embodiment; and

[0028] Fig. 9 is a block diagram of a display device according to an embodiment. DETAILED DESCRIPTION

[0029] In the following description of the present disclosure, when the detailed description of known functions and configurations incorporated herein may make the subject matter of the present disclosure unclear, the detailed description will be omitted. In addition, the following embodiments can be modified in a variety of different forms, and the scope of the technical spirit of the present disclosure is not limited to the following examples. On the contrary, these embodiments are provided so that the present disclosure will be thorough and complete, and the technical spirit will be fully conveyed to those skilled in the art.

[0030] However, it should be understood that the present disclosure is not limited to the specific embodiments described below, but includes various modifications, equivalents and / or substitutions of the embodiments of the present disclosure. Regarding the description of the drawings, like reference numerals may be used for like constituent elements.

[0031] Terms such as “first” and “second” used in various exemplary embodiments may modify various elements regardless of the order and / or importance of the corresponding elements, and do not limit the corresponding elements.

[0032] In the specification, the term "A or B", "at least one of A or / and B", or "one or more of A or / and B" may include all possible combinations of the items listed together. For example, the term "at least one of A or / and B" means: (1) including at least one A; (2) including at least one B; or (3) including both at least one A and at least one B.

[0033] Unless otherwise specified, singular expressions include plural expressions. It should be understood that terms such as "include" or "comprising" are used herein to indicate the existence of characteristics, quantities, steps, operations, elements, components or combinations thereof, without excluding the existence or possible addition of one or more other characteristics, quantities, steps, operations, elements, components or combinations thereof.

[0034] If a certain element (e.g., a first element) is described as being “operably or communicatively coupled to” or “connected to” another element (e.g., a second element), it should be understood that the certain element may be connected to the other element directly or through another element (e.g., a third element). On the other hand, if a certain element (e.g., a first element) is described as being “directly coupled to” or “directly connected to” another element (e.g., a second element), it should be understood that there is no element (e.g., a third element) between the certain element and the other element.

[0035] Moreover, the expression "configured to" used in the present disclosure may be used interchangeably with other expressions, such as "suitable for", "capable of", "designed to", "adapted to", "manufactured to", and "capable of", as appropriate. At the same time, the term "configured to" does not necessarily mean that the device is "specially designed to" in terms of hardware. On the contrary, in some cases, the expression "a device configured to..." may mean that the device is "capable of" performing operations together with another device or component. For example, the phrase "a processor configured to perform A, B, and C" may mean a dedicated processor (e.g., an embedded processor) for performing the corresponding operations or a general-purpose processor (e.g., a CPU or an application processor) that can perform the corresponding operations by executing one or more software programs stored in a memory device.

[0036] Hereinafter, various embodiments of the present disclosure will be described in more detail with reference to the accompanying drawings.

[0037] Figure 1 is a diagram of a display device according to an embodiment.

[0038] refer to Figure 1 , the display device 100 includes a plurality of modular displays 120 - 1 , 120 - 2 , 120 - 3 , and 120 - 4 arranged on a frame 110 . Figure 1 Four modular displays are shown, but this is only for ease of description, embodiments are not limited thereto and may be diversified in many different ways. More or less than four modular displays may be provided.

[0039] The frame 110 may be coupled with and support the plurality of modular displays 120 - 1 , 120 - 2 , 120 - 3 , and 120 - 4 .

[0040] In this case, the chassis 110 may protect the plurality of modular displays 120 - 1 , 120 - 2 , 120 - 3 , and 120 - 4 from the external environment or perform a function of absorbing light emitted from the modular displays.

[0041] Here, the frame 110 may be implemented as a metal material such as aluminum or a flexible material such as rubber, polyamide, or the like.

[0042] A plurality of modular displays 120-1, 120-2, 120-3, and 120-4 may be arranged on the rack 110 and coupled, and each of the plurality of modular displays 120-1, 120-2, 120-3, and 120-4 may be directly or indirectly connected to an adjacent modular display.

[0043] In this case, the modular displays may display images. For example, the lower left modular display 120-1 may display the lower left area of ​​the image, the lower right modular display 120-2 may display the lower right area of ​​the image, the upper left modular display 120-3 may display the upper left area of ​​the image, and the upper right modular display 120-4 may display the upper right area of ​​the image.

[0044] Since each of the plurality of modular displays 120 - 1 , 120 - 2 , 120 - 3 , and 120 - 4 has the same structure and function as one another, the description of the modular display 120 - 1 may be equally applied to the other modular displays 120 - 2 , 120 - 3 , and 120 - 4 included in the display apparatus 100 .

[0045] Reference zoomed in Figure 11, as a part of the display device 100, the modular display 120-1 includes a substrate 130 and a pixel, the pixel including a red inorganic light emitting element (e.g., a red micro LED, etc.), a green inorganic light emitting element (e.g., a green micro LED, etc.), and a blue inorganic light emitting element (e.g., a blue micro LED, etc.). That is, each of the plurality of modular displays 120-1, 120-2, 120-3, and 120-4 may include a corresponding plurality of pixels.

[0046] The substrate 130 may be in the form of a plate on which electronic components such as resistors, capacitors, etc. are fixed, and an electronic circuit is constructed by electrically connecting each electronic component.

[0047] In this case, a plurality of pixels may be formed, wherein each pixel is formed by correspondingly including a red inorganic light emitting element, a green inorganic light emitting element, and a blue inorganic light emitting element.

[0048] Specifically, a driving circuit for driving a red inorganic light emitting element, a green inorganic light emitting element, and a blue inorganic light emitting element is formed on the substrate 130. The red inorganic light emitting element, the green inorganic light emitting element, and the blue inorganic light emitting element can be mounted on the driving circuit so as to be electrically connected to the driving circuit. In this case, the driving circuit can drive the red inorganic light emitting element, the green organic light emitting element, and the blue organic light emitting element to emit light. The substrate 130 can be formed of glass. However, this is only an example, and the substrate 130 can be formed of polyimide or the like.

[0049] Since each pixel among the plurality of pixels has the same structure and function, description will be made by taking one pixel 140 among the plurality of pixels as an example.

[0050] In an embodiment, the pixel 140 may include a plurality of sub-pixels. Here, a sub-pixel is a sub-unit constituting a pixel, and each sub-pixel may be composed of an inorganic light-emitting element.

[0051] Therefore, the pixel 140 can represent or display an image by a combination of the colors of light emitted by the red inorganic light emitting element, the green inorganic light emitting element, and the blue inorganic light emitting element. In other words, the red inorganic light emitting element, the green inorganic light emitting element, and the blue inorganic light emitting element can emit light and form the pixel 140 of the modular display 120-1.

[0052] For example, the pixel 140 may be composed of a red inorganic light emitting element, a green inorganic light emitting element, and a blue inorganic light emitting element.

[0053] In this case, the red inorganic light emitting element may include an inorganic light emitting element and a color filter, and the white light emitted from the inorganic light emitting element may pass through a color filter including a red phosphor to form a sub-pixel displaying red. Alternatively, a sub-pixel displaying red may be formed by emitting light having a red wavelength in a light emitting element without a separate color filter. Sub-pixels displaying green or blue may be formed by applying different color filters or by emitting light having a green or blue wavelength accordingly.

[0054] The red inorganic light-emitting element, the green inorganic light-emitting element, and the blue inorganic light-emitting element can be implemented as a mini LED (light-emitting diode) or a micro LED (light-emitting diode). Here, a mini LED is a small inorganic light-emitting element that emits light by itself, meaning an LED chip with a size of about 100 to 200 microns. A micro LED is a tiny-sized inorganic light-emitting element that emits light by itself, meaning an LED chip with a size of about 5 to 100 microns.

[0055] Hereinafter, for convenience of description, it will be described that the red inorganic light emitting element, the green inorganic light emitting element, and the blue inorganic light emitting element according to the embodiment are implemented as micro LEDs.

[0056] In the above example, it has been described that one pixel 140 is composed of three inorganic light emitting elements, but this is only an example, and the number and color of the inorganic light emitting elements may be changed in many different ways.

[0057] In an embodiment, the pixel 140 may be composed of one inorganic light emitting element. In other words, one inorganic light emitting element may form one pixel 140. In this case, the inorganic light emitting element having multiple light emitting regions may emit light having different color wavelengths in each light emitting region. For example, one inorganic light emitting element may emit red light in a first region, blue light in a second region, and green light in a third region to form one pixel.

[0058] The pixel 140 may be formed on the substrate 130 , and a plurality of pixels may be arranged.

[0059] For example, a plurality of pixels may be arranged in a matrix form, where the pixels 140 are formed on the substrate 130 at constant intervals. In this case, the matrix may have the same number of rows and columns (e.g., in the case of M=N, a 1X1 array, a 2X2 array, etc., where M and N are natural numbers). However, this is only an example, and the number of rows and columns may be different (e.g., in the case of M≠N, a 2X3 array, a 3X4 array, etc., where M and N are natural numbers). However, this is only an example, and a plurality of pixels may be arranged in various forms such as a rhombus, a triangle, an S-striped shape, and the like.

[0060] Reference area A (which is Figure 1 ) and also in Figure 1 , a seam area 150 may be formed between the plurality of modular displays 120-1, 120-2, 120-3, and 120-4. Portions corresponding to the seam area 150 on the film formed on the plurality of modular displays may be transferred (or hardened, patterned), and a cover (or covering portion) 160 formed by removing the remaining portion of the film except the transferred portion may cover the seam area 150.

[0061] If the difference between the optical density of cover 160 and the optical density of the remaining modular display parts except cover 160 is greater than or equal to a predetermined value, the user may feel unnatural when recognizing the screen of the display device as an integrated screen. Therefore, in order to avoid this, a film having an optical density within a predetermined range (e.g., + / - 20%) based on the optical densities of the plurality of modular display parts is transferred to a portion corresponding to seam area 150, and thus cover 160 can be formed.

[0062] Therefore, it is possible to provide the display device 100 having the integrated screen in which the seam area 150 is covered by the cover 160. In addition, it is possible to provide a display device in which the contrast ratio can be improved to achieve a deep black and the color gamut can be improved.

[0063] In the following, reference will be made to Figure 2 , Figure 3A , Figure 3B , Figure 4A , Figure 4B , Figure 5A , Figure 5B , Figure 6 , Fig. 7A , Figure 7B and Figure 8 A method for manufacturing the display device 100 and a structure of the display device 100 according to an embodiment are described in more detail.

[0064] Figure 2 is a flowchart describing a method for manufacturing a display device according to an embodiment.

[0065] refer to Figure 2 In step S210, a plurality of modular displays are arranged on a rack.

[0066] The frame 110 is used to support the plurality of modular displays 120 - 1 , 120 - 2 , 120 - 3 , and 120 - 4 , and the size of the frame 110 may be determined by the number and size of the plurality of modular displays 120 - 1 , 120 - 2 , 120 - 3 , 120 - 4 , and the like.

[0067] refer to Figure 3A , the plurality of modular displays 120-1, 120-2, 120-3, and 120-4 may be arranged in a matrix form (e.g., M x N, where M and N are natural numbers). As an embodiment, the plurality of modular displays may be arranged in equal numbers of rows and columns (e.g., in the case of M=N, a 3x3 array, a 5x5 array, etc., where M and N are natural numbers). In an embodiment, the plurality of modular displays may be arranged in different numbers of rows and columns (e.g., in the case of M≠N, a 3x2 array, a 5x4 array, etc., where M and N are natural numbers).

[0068] refer to Figure 3B , a plurality of modular displays 120 - 1 and 120 - 2 may be arranged on the frame 110 , and a seam area 150 may be formed between the modular displays 120 - 1 and 120 - 2 adjacent to each other.

[0069] The seam area 150 may be an area having a width d1 between adjacent modular displays 120 - 1 and 120 - 2 and having a thickness of the modular display 121 as a height.

[0070] Specifically, the width d1 of the joint region 150 is defined by the following mathematical formula 1.

[0071] Mathematical formula 1: d1 = d3 - 2 * d2

[0072] Here, the distance between the center of pixel 141-1 located on the modular display 120-1 adjacent to the seam area 150 and one side of the modular display 120-1 is d2, and the center distance between pixels 141-1 and 141-2 (for example, the distance between the centers of pixels 141-1 and 141-2) is d3, where pixel 141-1 is located on the modular display 120-1 and pixel 141-2 is located on the modular display 120-2.

[0073] Pixels 141-1 and 142-1 (adjacent pixels formed on a single modular display 120-1, such as Figure 3B The center distance d4 of the image may be equal to the center distance d3. In this case, the degradation of image quality and the unnaturalness felt by the user's naked eyes may be minimized.

[0074] To this end, when a plurality of modular displays 120-1 and 120-2 are arranged on the frame 110, the plurality of modular displays 120-1 and 120-2 may be arranged by determining a width d1 of the seam area 150 based on a distance d2 between a center of a pixel 141-1 and a side of the modular display 120-1 and a center distance d4 of pixels 141-1 and 142-1 formed on the same modular display 120-1.

[0075] However, in some cases, position errors or tilts may occur during the arrangement of multiple modular displays, and depending on the number of arrangements, the errors may gradually accumulate so that the width d1 of the seam area 150 may not be a uniform value (e.g., 5 to 100 microns) in all seam areas.

[0076] However, according to the embodiment, even if the width d1 of the seam area 150 is not uniformly formed, the seam area 150 can be effectively covered by using a transfer film and a laser, which will be referred to in detail. Figure 4A , Figure 4B , Figure 5A , Figure 5B and Figure 6 Describe in more detail.

[0077] refer to Figure 2 , in step S220, a film is formed on a plurality of modular displays.

[0078] In this case, if Figure 4A As shown, a film 410 may be formed on the plurality of modular displays and the seam area 150 so as to cover the plurality of modular displays and the seam area 150 .

[0079] refer to Figure 4B , the film 410 may include a base film 411 and a transfer film 412. In this case, the transfer film 412 may be attached to the base film 411.

[0080] Specifically, the film 410 means a film made in the form of a dry film having a laminated structure including a base film 411 and a transfer film 412 and the like.

[0081] In this case, the base film 411 may be implemented with a transparent polymer material to prevent the transfer film 412 from being damaged or contaminated and to transfer light or light and heat to the transfer film 412. For example, the base film 411 may be implemented with polyester, polyacrylic, polyepoxy, polyethylene, polystyrene, etc.

[0082] The transfer film 412 may include a photosensitive resin, a photoinitiator, a thermosetting resin, etc. that undergoes a photochemical reaction on a portion irradiated with light having a specific wavelength (e.g., X-rays, ultraviolet rays (UV), extreme UV (EUV), lasers, etc.). The color of the transfer film 412 may be determined by a dye. According to an embodiment, the color of the transfer film 412 covering the seam area 150 may be dark, such as black, and its optical density may be determined according to the optical density of a plurality of modular displays. However, the embodiment is not limited thereto, and various modifications may be made.

[0083] The film 410 may be formed on the plurality of modular displays and the seam area by lamination. In this case, lamination refers to a method of covering a film on a surface of an object to be laminated to form a layer.

[0084] Specifically, the film 410 may be laminated on a plurality of modular displays such that the transfer film 412 is disposed to face the plurality of modular displays.

[0085] For example, a roll lamination method can be used to attach the film 410 to the plurality of modular displays by delivering and pressing the plurality of modular displays and the film 410 formed on the plurality of modular displays between rollers. Alternatively, the film 410 formed on the plurality of modular displays can be compressed using a vacuum lamination method using a vacuum, thereby attaching the film 410 to the plurality of modular displays. However, the embodiment is not limited thereto, and this can be achieved in various ways, such as using rollers, vacuum, heating or cooling, etc., or any combination thereof.

[0086] After attaching the film 410 to the plurality of modular displays, if bubbles exist between the film 410 and the plurality of modular displays, the bubbles may be removed using an autoclave method. For example, the bubbles may be removed via a constant temperature pressure treatment process in which pressure is applied while maintaining a uniform temperature or a hot press treatment process in which pressure is applied while increasing a temperature.

[0087] like Figure 4B As shown, the transfer film 412 may have a predetermined thickness h2 according to the height h1 of the inorganic light emitting element 140. For example, as described below, a portion of the transfer film 412 may be attached to the seam area 150 to cover the seam area 150. Therefore, since the angle of light emitted from the inorganic light emitting element 140 may be limited by the transfer film 412 attached to the seam area 150, the transfer film 412 may have a predetermined thickness according to the inorganic light emitting element 140. For example, the thickness of the transfer film 412 may be 1.5 times or less of the height of the inorganic light emitting element 140.

[0088] Return to reference Figure 2 , in step S230, a cover is formed between the light emitting elements of the plurality of modular displays by removing areas of the film corresponding to the light emitting elements of the plurality of modular displays.

[0089] refer to Figure 5A and Figure 5B, a portion of the film 410 corresponding to an edge of an adjacent modular display (e.g., a seam area 150 formed between a plurality of modular displays, etc.) may be irradiated with light (e.g., laser, etc.), and the portion of the film 410 corresponding to the seam area 150 may be transferred. Here, the laser 510 is monochromatic light having straightness, and may be implemented with a common laser such as a solid laser, a gas laser, a semiconductor laser, a dye laser, or the like.

[0090] Specifically, the laser 510 can be irradiated on a portion of the transfer film 412 through the base film 411. In order to prevent the transfer portion from being removed during the removal of the base film 411, the transfer portion can be transferred so that the surface attached to the modular display can have a stronger adhesion than the surface attached to the base film. In other words, transferring a specific portion of the film can mean processing a specific portion of the film so that the adhesion of the specific portion is stronger than the adhesion of other portions. For example, transferring a specific portion can mean enhancing the adhesion of the specific portion to the surface of the modular display or weakening the adhesion of other portions to the surface of the modular display.

[0091] In an embodiment, a photothermal conversion reaction may occur at the portion of the transfer film 412 irradiated by the laser 510, thereby releasing heat, and the portion corresponding to the seam area 150 may be transferred (or attached) to the surface of the modular display (i.e., the edge of the adjacent modular display) by the heat emitted. In an embodiment, a photochemical reaction may occur at the portion of the transfer film 412 irradiated by the laser 510, and the portion corresponding to the seam area 150 may be transferred (or attached) to the surface of the modular display. In other words, the laser 510 may cause a chemical change that allows a portion of the transfer film 412 including the photoresist to be removed by a solution (i.e., a developer) according to the type (negative or positive) of the transfer film 412. In this case, if the type of the transfer film 412 is positive, the portion of the transfer film 412 irradiated by the laser 510 may be dissolved in the solution. In other cases, if the type of the transfer film 412 is a negative type, the portion of the transfer film 412 not irradiated by the laser 510 (the remaining portion of the transfer film 412 except the portion of the transfer film 412 irradiated by the laser 510 ) may be dissolved in the solution.

[0092] A portion of the film 410 corresponding to the seam region 150 will cover the seam region 150 and may be transferred to have a width greater than that of the seam region 150 and less than a distance between adjacent pixels among the plurality of pixels.

[0093] As mentioned above Figure 3A and Figure 3BAs described above, when the width of the seam region 150 varies according to the position, the width of the portion corresponding to the seam region 150 should be greater than the width of the seam region 150 itself. The width of the portion corresponding to the seam region 150 may vary according to the position.

[0094] As an embodiment, the portion of the film 410 corresponding to the seam area 150 between the multiple modular displays can be detected by optical inspection, the detected portion can be irradiated with a laser, and the portion corresponding to the seam area 150 can be transferred (or attached) to the edges of adjacent modular displays 120-1 and 120-2.

[0095] Specifically, the optical inspection can detect the seam area 150 between the plurality of modular displays by taking an image of the film 410 using a visual camera, such as an automatic optical inspection (AOI). In this case, the portion of the film 410 corresponding to the seam area 150 can be detected based on the detected seam area 150 and a plurality of inter-pixel distances. The optical inspection can be achieved by moire fringes (fringe generated by a frequency difference between wavelengths), halogen transmission, laser transmission, etc.

[0096] Thereafter, a laser beam is radiated while moving a light source along a portion of the film 410 corresponding to the detected seam area 150 , thereby transferring the portion of the film 410 corresponding to the seam area 150 from the film 410 .

[0097] In an embodiment, before forming a film on a plurality of modular displays, an optical inspection may be performed to detect the seam area 150, and then, after forming the film on the plurality of modular displays, a laser may be radiated onto a portion of the film according to the detected seam area 150 so as to transfer a portion of the film corresponding to the seam area 150.

[0098] In this way, irradiating the laser 510 to the portion of the film 410 corresponding to the seam area 150 through optical inspection effectively covers the seam area 150 with the film 410, the width of which may vary depending on the position due to the dimensional tolerance of the modular display or the tolerance that may arise when arranging multiple modular displays on a rack.

[0099] refer to Figure 6 , the cover 160 may be formed by removing areas of the base film 411 and the transfer film 412 that are not irradiated with the laser.

[0100] Specifically, the base film 411 may be removed by applying physical pressure upward relative to the base film 411. The method of removing the base film 411 may be implemented by a vacuum adsorption method, a roll pressing method, or the like.

[0101] In this case, in the area (or portion) of the transfer film 412 that is not irradiated by the laser, the adhesion force attached to the surface of the modular display is relatively weaker than the adhesion force of the surface attached to the base film, and therefore, when the base film 411 is removed, the portion of the transfer film 412 that is not irradiated by the laser can be removed together.

[0102] Also, in the transferred portion, adhesion to the surface of the modular display is relatively stronger than adhesion to the surface of the base film, and thus, when the base film 411 is removed, the portion transferred from the transfer film may not be removed.

[0103] Therefore, when the base film 411 is removed, the area (or portion) of the transfer film 412 that is not irradiated by the laser is removed together with the base film 411, while the portion of the transfer film irradiated by the laser beam remains attached to the modular display, and a cover 160 that can cover the seam area 150 can be formed.

[0104] like Fig. 7A and Figure 7B As shown, a display device manufactured according to an embodiment may have a frame 110, a plurality of modular devices 120-1, 120-2, 120-3 and 120-4 arranged on the frame 110, and a cover 160 covering a seam area formed between the plurality of modular displays 120-1, 120-2, 120-3 and 120-4 (without considering tolerances occurring when arranging the plurality of modular displays).

[0105] refer to Figure 7B An enlarged view of the cover 160 , the cover 160 can be attached to multiple modular displays 120 - 1 and 120 - 2 to cover the seam area 150 , and the cover 160 can be attached to different modular displays 120 - 1 and 120 - 2 in the seam area 150 to fill at least a portion of the seam area 150 .

[0106] Specifically, in Figure 2 The cover formed in step S230 can be attached to the sides (i.e., edges) of different modular displays 120-1 and 120-2 in the seam area 150 to fill at least a portion of the seam area 150, thereby fixing the intervals between the multiple modular displays 120-1 and 120-2 to remain constant.

[0107] like Figure 7BAs shown, the wires 710-1 and 710-2 may be formed on the outer sides of the substrates 130-1 and 130-2 of the plurality of modular displays 120-1 and 120-2. For example, when the substrates 130-1 and 130-2 of the plurality of modular displays 120-1 and 120-2 are implemented with glass, it is difficult to form a hole through the glass due to the characteristics of the glass. Therefore, the wires 710-1 and 710-2 connecting the driving circuits disposed on the upper portions of the substrates 130-1 and 130-2 and other circuits disposed below the substrates 130-1 and 130-2 may be disposed on the sides of the substrates 130-1 and 130-2. In this case, since the cover 160 can be formed of a non-conductive insulating material, the cover 160 can maintain the spacing and seam area 150 between the multiple modular displays 120-1 and 120-2 so as to prevent the corresponding wires 710-1 and 710-2 formed in the multiple different modular displays 120-1 and 120-2 from short-circuiting.

[0108] Figure 8 is a diagram illustrating an additional method of manufacturing a display device according to an embodiment.

[0109] refer to Figure 8 , before removing the remaining portion of the film except the transferred portion, a portion of the film corresponding to at least one pixel formed on each of the plurality of modular displays may be transferred. In other words, forming the cover may include forming the cover between the light emitting elements of each modular display.

[0110] Specifically, the portion corresponding to at least one pixel may be a boundary portion of a matrix including at least one of a plurality of pixels formed at regular intervals. In this case, the matrix may have the same number of rows and columns (e.g., in the case of M=N, 1x1 array, 2x2 array, etc., where M and N are natural numbers). However, this is only an example, and the number of rows and columns may be different (e.g., in the case of M≠N, 2x3 array, 3x4 array, etc., where M and N are natural numbers). However, this is only an embodiment, and the portion corresponding to at least one pixel may be implemented in various forms as a portion that does not cover the upper portion of the pixel.

[0111] To this end, when a seam area between multiple modular displays in a film is detected by optical inspection, information such as the position and size of multiple pixels formed in each of the multiple modular displays can be detected based on information such as the detected seam area, the size of a predetermined modular display, and the position, number, size and spacing of pixels formed in the modular display.

[0112] Thereafter, a portion corresponding to the seam area 150 may be transferred from the film 410 by irradiating the film 410 with laser light while moving a light source emitting laser light along an area corresponding to the detected seam area 150, and then, the Figure 8 The display device shown in , in which the cover 160 is formed by removing the remaining portion of the film except the transfer portion.

[0113] According to the above-described embodiment, the cover 160 can be formed symmetrically and repeatedly at regular intervals between a plurality of pixels, and thus the user can feel a sense of proportion, uniformity, etc. Therefore, a display device can be provided with which the user can more effectively recognize the screens of a plurality of modular displays as an integrated screen.

[0114] Fig. 9 is a block diagram of a display device according to an embodiment.

[0115] refer to Fig. 9 , the display device 100 includes a plurality of modular displays 910 - 1 , 910 - 2 , . . . , 910 - n and a processor 920 .

[0116] The plurality of modular displays 910-1, 910-2, ..., 910-n may each include a plurality of pixels composed of a red inorganic light emitting element, a green inorganic light emitting element, and a blue inorganic light emitting element. Figure 1 A detailed description of a plurality of modular displays 910 - 1 , 910 - 2 , . . . , 910 - n is given.

[0117] Moreover, a plurality of modular displays 910-1, 910-2, ..., 910-n can be arranged in a matrix form on a frame, wherein a seam area formed between the plurality of modular displays 910-1, 910-2, ..., 910-n is covered by a portion of the film attached to the plurality of modular displays due to transfer of a portion corresponding to the seam area from a film formed on the plurality of modular displays and the seam area.

[0118] The transfer film may have a preset thickness based on the heights of the red, green, and blue inorganic light emitting elements included in the plurality of pixels. Specific details of covering the seam area with a film have been described above.

[0119] The processor 920 controls the overall operation of the display apparatus 100. To this end, the processor 920 may include one or more of a central processing unit (CPU), an application processor (AP), or a communication processor (CP).

[0120] The processor 920 may control the plurality of modular displays 910 - 1 , 910 - 2 , . . . , 910 - n to display images.

[0121] The image may be received from an external device or pre-stored in a memory of the display apparatus 100 .

[0122] Specifically, the processor 920 may control the plurality of modular displays 910-1, 910-2, ..., 910-n to crop images corresponding to their positions in the display device 100 through the plurality of modular displays 910-1, 910-2, ..., 910-n and play the cropped images.

[0123] For example, the processor 920 may divide an image into a plurality of regions based on the number of modular displays constituting the display device 100 and the format in which the modular displays are arranged in the display device 100, and display the divided image on the modular displays existing at corresponding positions.

[0124] For example, the processor 920 may display an image in a region located on the upper left side among the plurality of regions on the modular display located on the upper left side of the display device 100 .

[0125] Therefore, the processor 920 may display the entire image through the plurality of modular displays 910 - 1 , 910 - 2 , . . . , 910 - n .

[0126] Each modular display may be provided with a timing controller for controlling the inorganic light emitting element of the modular display to display an image. Each modular display may display an image through pixels under the control of the processor 920. However, this is only an example, and the timing controller may be provided by a set consisting of a predetermined number of modular displays, and under the control of the processor 920, the timing controller may control the modular displays included in each set and display an image through pixels.

[0127] Although preferred embodiments have been shown and described, the present disclosure is not limited to specific embodiments, and it should be understood that the present disclosure is not limited to specific embodiments as described above. It will be understood by those skilled in the art that various changes can be made in form and details without departing from the spirit and scope defined by the appended claims and their equivalents.

Claims

1. A method for manufacturing a display device comprising a plurality of modular displays, the method comprising: include: Arranging the plurality of modular displays on a rack, each of the plurality of modular displays comprising a corresponding plurality of pixels, the plurality of pixels comprising a red inorganic light emitting element, a green inorganic light emitting element, and a blue inorganic light emitting element; forming a film on the plurality of modular displays; inspecting, by optical inspection, a portion of the film corresponding to a seam area formed between adjacent ones of the plurality of modular displays; irradiating a portion of the film corresponding to the seam area with a laser; as well as A cover is formed over the seam area by removing portions of the film other than the irradiated portions.

2. The method according to claim 1, in, The covering fills at least a portion of the seam area.

3. The method according to claim 1, in, The film includes a base film and a transfer film attached to the base film, and Wherein, forming the film includes laminating the film on the plurality of modular displays such that the transfer film is disposed to face the plurality of modular displays.

4. The method according to claim 3, in, The forming of the cover includes forming the cover by removing areas of the base film and the transfer film that are not irradiated with laser light.

5. The method according to claim 3, in, The thickness of the transfer film is based on the heights of the red inorganic light emitting element, the green inorganic light emitting element, and the blue inorganic light emitting element.

6. A display device, include: frame; a plurality of modular displays arranged on the frame such that a seam area is formed between adjacent modular displays in the plurality of modular displays; a processor configured to control the plurality of modular displays to display images, the Each modular display of the plurality of modular displays comprises: substrate; and A plurality of pixels on the substrate respectively include a red inorganic light emitting element, a green inorganic light emitting element and a blue inorganic light emitting element; and a cover covering the seam area and attached to respective edges of the adjacent modular displays defining the seam area, Wherein, the covering is formed by the following operations: forming a film on the plurality of modular displays; inspecting a portion of the film corresponding to the seam area by optical inspection; irradiating a portion of the film corresponding to the seam area with a laser; and The cover is formed by removing portions of the film except for the irradiated portions.

7. The display device according to claim 6, in, The cover fills at least a portion of the seam area between the respective edges of the adjacent modular displays.

8. The display device according to claim 6, in, The cover includes a transfer film that has been irradiated with a laser to attach the transfer film to the respective edges of the adjacent modular displays that define the seam area, and The thickness of the transfer film is based on the heights of the red inorganic light-emitting element, the green inorganic light-emitting element, and the blue inorganic light-emitting element.

9. The display device according to claim 6, in, The width of the overlay is less than a distance between adjacent pixels of the plurality of pixels and greater than a distance between the respective edges of the adjacent modular displays of the plurality of modular displays.

Images