Micro-lens array having color-conversion function, micro-LED display module including micro-lens array, and method for manufacturing micro-lens array

1. A micro-lens array included in a micro-LED display module using a micro LED as a light emitting material, comprising:

a body;

a bank portion recessed inward from one surface of the body in one-to-one correspondence to each of micro-LEDs;

a lens part protruding on an opposite surface of the body in one-to-one correspondence to each of the micro-LEDs;

a barrier rib formed between the bank portions; and

a color converter included in the bank portion and configured to convert color of light emitted from each of the micro-LEDs.

2. The micro-lens array of claim 1 , wherein the color converter is integrally formed with the body by injecting quantum dot (QD) ink into the bank portion and curing the QD ink.

3. The micro-lens array of claim 2 , wherein the micro-LED is a blue LED for emitting blue light, and

wherein the color converter includes:

a green converter formed by injecting quantum dot (QD) ink for converting light emitted from the blue LED to green light and curing the QD ink;

a red converter formed by injecting quantum dot (QD) ink for converting blue light emitted from the blue LED to red light and curing the QD ink; and

a space portion for emitting the blue light emitted from the blue LED without changes.

4. The micro-lens array of claim 1 , further comprising:

A first light absorption layer formed on a bottom surface of the barrier rib to absorb light incident on the bottom surface of the barrier rib.

5. The micro-lens array of claim 1 , further comprising:

A light reflection layer formed on a side surface of the bank portion to reflect light emitted to the side surface of the bank portion.

6. The micro-lens array of claim 1 , further comprising:

a second light absorption layer formed in a region between the lens parts on an opposite surface of the body to absorb the light emitted to the region between the lens parts.

7. The micro-lens array of claim 1 , further comprising:

an air layer that is recessed in a direction toward the lens part at an edge of a bottom surface of the bank portion and totally reflects light emitted to the region between the lens parts.

8. The micro-lens array of claim 1 , wherein a bottom surface of the bank portion is convex in a direction toward the lens part to allow light passing through the color converter to be condensed to the lens part.

9. A micro-LED display module using a micro LED as a light emitting material and including a substrate with the micro LED, and a micro-lens array provided above the substrate, the micro-lens array comprising:

a body;

a bank portion recessed inward from one surface of the body in one-to-one correspondence to each of the micro-LEDs;

a lens part protruding on an opposite surface of the body in one-to-one correspondence to each of the micro-LEDs;

a barrier rib formed between the bank portions; and

a color converter included in the bank portion and configured to convert color of light emitted from each of the micro-LEDs.

10. The micro-LED display module of claim 9 , wherein the micro-lens array is attached and coupled to an upper part of the substrate by an optical clear adhesive (OCA).

11. The micro-LED display module of claim 9 , wherein the color converter is integrally formed with the body by injecting quantum dot (OD) ink into the bank portion and curing the QD ink.

12. The micro-LED display module of claim 11 , wherein the micro-LED is a blue LED for emitting blue light, and

wherein the color converter includes:

a green converter formed by injecting quantum dot (QD) ink for converting light emitted from the blue LED to green light and curing the QD ink;

a red converter formed by injecting quantum dot (QD) ink for converting blue light emitted from the blue LED to red light and curing the QD ink; and

a space portion for emitting blue light emitted from the blue LED without change.

13. The micro-LED display module of claim 9 , wherein the micro-lens array further includes a first light absorption layer formed on a bottom surface of the barrier rib to absorb light incident on the bottom surface of the barrier rib.

14. The micro-LED display module of claim 9 , wherein the micro-lens array further includes a light reflection layer formed on a side surface of the bank portion to reflect light emitted to the side surface of the bank portion.

15. The micro-LED display module of claim 14 , wherein the micro-lens array further includes an air layer that is recessed in a direction toward the lens part at an edge of a bottom surface of the bank portion and totally reflects light emitted to the region between the lens parts.

16. The micro-LED display module of claim 14 , wherein a bottom surface of the bank portion is convex in a direction toward the lens part to allow light passing through the color converter to be condensed to the lens part.

17. The micro-LED display module of claim 9 , wherein the micro-lens array further includes a second light absorption layer formed in a region between the lens parts on an opposite surface of the body to absorb the light emitted to the region between the lens parts.

18. A method of manufacturing a micro-lens array included in a micro-LED display module using a micro LED as a light emitting material and including a body, a bank portion recessed inward from one surface of the body in one-to-one correspondence to each of micro-LEDs, a lens part protruding on an opposite surface of the body in one-to-one correspondence to each of the micro-LEDs, a barrier rib formed between the bank portions, and a color converter included in the bank portion and configured to convert color of light emitted from each of the micro-LEDs, the method comprising:

a mold preparation operation of preparing a first mold having one surface, on which an engraved shape of the lens part is formed, and a second mold having one surface, on which an embossed shape of the bank portion is formed;

a mold alignment operation of aligning the first mold and the second mold with each other on a base mold in a state of being spaced apart at a predetermined interval to allow the engraved shape of the lens part and the embossed shape of the bank portion to be arranged in one-to-one correspondence to each other;

a polymer injection and curing operation of forming the body including the lens part and the bank portion by injecting transparent polymer into a space between the first mold and the second mold and curing the transparent polymer; and

a color converter forming operation of forming the color converter in the bank portion.

19. The method of claim 18 , wherein the micro-LED is a blue LED for emitting blue light, and the color converter includes a green converter configured to convert light emitted from the blue LED to green light, a red converter configured to convert blue light emitted from the blue LED to red light, and a space part configured to emit the blue light emitted from the blue LED without change, and

wherein the color converter forming operation includes:

forming the green converter by injecting quantum dot (QD) ink for converting light emitted from the blue LED to green light into a part of the bank portion and curing the QD ink; and

forming the red converter by injecting quantum dot (QD) ink for converting blue light emitted from the blue LED to red light into a part of the bank portion and curing the QD ink.

20. The method of claim 18 , further comprising:

forming a first light absorption layer on a bottom surface of the barrier rib to absorb light incident on the bottom surface of the barrier rib.