CN110556395A - 微型发光元件、图像显示元件及其制造方法 - Google Patents

微型发光元件、图像显示元件及其制造方法 Download PDF

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CN110556395A
CN110556395A CN201910468565.5A CN201910468565A CN110556395A CN 110556395 A CN110556395 A CN 110556395A CN 201910468565 A CN201910468565 A CN 201910468565A CN 110556395 A CN110556395 A CN 110556395A
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light
electrode
image display
micro light
emitting element
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CN110556395B (zh
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井口胜次
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Sharp Corp
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Sharp Corp
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    • HELECTRICITY
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    • H01L25/18Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof the devices being of types provided for in two or more different subgroups of the same main group of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N
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    • H01L25/16Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof the devices being of types provided for in two or more different main groups of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. forming hybrid circuits
    • H01L25/167Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof the devices being of types provided for in two or more different main groups of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. forming hybrid circuits comprising optoelectronic devices, e.g. LED, photodiodes
    • GPHYSICS
    • G09EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09GARRANGEMENTS OR CIRCUITS FOR CONTROL OF INDICATING DEVICES USING STATIC MEANS TO PRESENT VARIABLE INFORMATION
    • G09G3/00Control arrangements or circuits, of interest only in connection with visual indicators other than cathode-ray tubes
    • G09G3/20Control arrangements or circuits, of interest only in connection with visual indicators other than cathode-ray tubes for presentation of an assembly of a number of characters, e.g. a page, by composing the assembly by combination of individual elements arranged in a matrix no fixed position being assigned to or needed to be assigned to the individual characters or partial characters
    • G09G3/22Control arrangements or circuits, of interest only in connection with visual indicators other than cathode-ray tubes for presentation of an assembly of a number of characters, e.g. a page, by composing the assembly by combination of individual elements arranged in a matrix no fixed position being assigned to or needed to be assigned to the individual characters or partial characters using controlled light sources
    • G09G3/30Control arrangements or circuits, of interest only in connection with visual indicators other than cathode-ray tubes for presentation of an assembly of a number of characters, e.g. a page, by composing the assembly by combination of individual elements arranged in a matrix no fixed position being assigned to or needed to be assigned to the individual characters or partial characters using controlled light sources using electroluminescent panels
    • G09G3/32Control arrangements or circuits, of interest only in connection with visual indicators other than cathode-ray tubes for presentation of an assembly of a number of characters, e.g. a page, by composing the assembly by combination of individual elements arranged in a matrix no fixed position being assigned to or needed to be assigned to the individual characters or partial characters using controlled light sources using electroluminescent panels semiconductive, e.g. using light-emitting diodes [LED]
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Abstract

一种在内置有微型发光元件(100)的驱动电路的驱动电路基板(50)之上,连接了所述微型发光元件(100)的图像显示元件,上述微型发光元件(100)在与上述驱动电路的接合面的相反侧具有光出射面,上述微型发光元件(100)的结合面侧的表面与上述驱动电路基板(50)的结合面侧的表面中的任一个具有凹凸形状,上述微型发光元件(100)的P电极(19P)与N电极(19N)、和上述驱动电路基板(50)侧的P侧电极(51)与N侧电极(52)经由金属纳米粒子(30)而连接,上述微型发光元件(100)的结合面侧的表面与上述驱动电路基板(50)的结合面侧的表面之间所形成的空隙填充有光固化树脂(31)。由此,抑制材料不同的微型发光元件(100)与驱动电路基板(50)的温度上升并使它们贴合。

Description

微型发光元件、图像显示元件及其制造方法
技术领域
本发明涉及微型发光元件、图像显示元件及其制造方法。
背景技术
提出一种在驱动电路基板上具备多个构成像素的微型发光元件的显示元件。作为这样的显示元件,例如,专利文献1中公开有一种显示彩色图像的小型显示元件。在该显示元件中,在硅基板上形成驱动电路,并在其上配置有微小的紫外线发光二极管(LED:LightEmitting Diode)阵列。此外,在该显示元件中,在紫外线发光二极管之上设置有将紫外线光转换成红色、绿色以及蓝色的可见光的波长转换层。
这种显示元件不但小型,且具有亮度高,耐久性也高等的特性。因此,有望作为眼镜型终端、平视显示器(HUD)等显示装置用的显示元件。
此外,在这种显示元件中,构成驱动电路基板以及微型发光元件的材料不同,需要将两者进行贴合的工序。(参照专利文献1以及2)。
现有技术文献
专利文献
专利文献1:日本国公开专利公报“2002-141492号公报(2002年5月17日公开)”
专利文献2:美国公开专利公报“第US2011/0035925号说明书(2011年2月17日公开)”
发明内容
本发明所要解决的技术问题
在已形成有驱动电路的LSI上贴附微型LED而制造微型投影仪用显示装置的工序中,在已形成有驱动电路LSI的晶圆上,贴附成为发光部的微型LED组,需要将每个微型LED的电极相对于驱动电路的电极一一对应地电连接。一个微型LED的大小为50μm至数μm左右,微型LED的数量为数万个至数百万个。因此,一个电极的大小在1μm左右至10μm左右非常小。另外,构成微型LED的GaN层、或作为生长基板的蓝宝石基板相对于构成通常驱动电路的硅基板的热膨胀系数差异大,若在贴合工序中升温,则根据热膨胀系数之差,驱动电路LSI上的电极与微型LED的电极的设计位置会偏移,发生小电极彼此不重叠的情况。即使通过在升温状态下以恰好重叠的方式配置图案而连接,只要回到室温,也会产生大的热应力而破裂。
为了避免这样的问题,在专利文献2中,提出一种以不升温而连接的方法,但必须设置特殊的圆筒状的电极结构用以连接,难以应用于微细的电极。此外,为了连接,需要施加大的应力,若使显示元件高分辨率化,增加连接的电极数,则需要施加非常大的应力。从这样的理由出发,专利文献2所公开的方法难以应用于高分辨率显示元件。
本发明是鉴于上述问题而完成的,其目的在于,提供一种在结合电极数多且其电极尺寸小的结合中,抑制温度上升,并且适当地结合电极的方法。
解决问题的方案
(1)本发明的一实施方式是一种图像显示元件,在所述图像显示元件中,在内置有微型发光元件(light emission element)的驱动电路的驱动电路基板(drive circuitsubstrate)之上,连接了多个所述微型发光元件的图像显示元件(image displaydevice),上述微型发光元件在与上述驱动电路的结合面(bonding surface)的相反侧具有光出射面,
在上述微型发光元件的结合面侧的表面与上述驱动电路基板的结合面侧的表面的至少一个表面中具有凹凸形状,
上述微型发光元件的电极与上述驱动电路的基板侧的电极经由金属纳米粒子连接,
上述微型发光元件的结合面侧的表面与上述驱动电路基板的结合面侧的表面之间所形成的空隙(space)填充有光固化树脂(photo-curing resin)。
(2)此外,本发明的一实施方式的图像显示元件是在上述(1)的构成的基础上,在上述图像显示元件的由发光的像素构成的像素区域的外周,由与微型发光元件相同的材料而构成的虚设元件、以及对应于上述虚设元件的虚设电极被配置在上述驱动电路基板上,上述虚设元件与上述驱动电路基板之间的空隙与上述像素区域不同。
(3)此外,本发明的一实施方式在上述(2)的构成的基础上,上述虚设元件与上述驱动电路基板之间的空隙的图案根据上述像素区域的边而不同。
(4)本发明的一实施方式是一种图像显示元件的制造方法,包括:
在生长基板上形成由化合物半导体构成的微型发光元件的工序;形成包含驱动电路的驱动电路基板的工序;
将金属纳米粒子排列在上述微型发光元件的结合面和驱动电路基板的结合面中的任一个的工序;
在上述驱动电路基板上配置上述微型发光元件的工序;
在上述驱动电路基板上将光固化树脂注入上述微型发光元件之间的工序;以及向上述光固化树脂照射光并使其固化的工序。
(5)此外,本发明的一实施方式的制造方法是在上述(4)的构成的基础上,向上述光固化树脂照射光并使其固化的工序通过上述生长基板而进行的图像显示元件。
(6)此外,本发明的一实施方式的图像显示元件的制造方法在上述(4)的构成的基础上,将上述微型发光元件配置在上述驱动电路基板上的工序包含向与上述微型发光元件同时形成的虚设元件部注入光固化树脂,并通过光照射固化的工序。
发明效果
根据本发明的一个方式,抑制温度上升且能够实现现有的装置所不能实现的、结合电极数多且其电极尺寸小的结合。
附图说明
图1是根据本发明的第一实施方式的图像显示元件的像素部的剖视图。
图2是根据本发明的第一实施方式的微型发光元件的俯视图。
图3是根据本发明的第一实施方式的微型发光元件的制造工序。
图4是根据本发明的第一实施方式的图像显示元件的制造工序。
图5的(a)是根据本发明的第一实施方式的图像显示元件的俯视图,图5的(b)、(c)是根据本发明的第一实施方式的图像显示元件的外周部的剖视图。
图6A是根据本发明的第一实施方式的变形例的微型发光元件的俯视图。
图6B是根据本发明的第一实施方式的另一变形例的微型发光元件的俯视图。
图7是根据本发明的第二实施方式的图像显示元件的剖视图。
图8是根据本发明的第二实施方式的微型发光元件的制造工序。
图9是根据本发明的第二实施方式的图像显示元件的制造工序。
图10是根据本发明的第三实施方式的图像显示元件的制造工序。
图11是根据本发明的第三实施方式的微型发光元件的制造工序。
图12是根据本发明的第三实施方式的图像显示元件的制造工序。
图13是根据本发明的第四实施方式的微型发光元件的制造工序。
具体实施例
〔第一实施方式〕
以下,说明本发明的一实施方式。
〔图像显示元件的构造的概要〕
下面,例举出以搭载多个微型发光元件100作为光源的图像显示元件200为例,并参照附图(图1等)说明本发明的实施方式。并且,图像显示元件200在像素区域(pixel region)1(图5)具有多个微型发光元件100。此外,图像显示元件200具备用于向微型发光元件100供给电流,并使其发光的驱动电路基板50。微型发光元件100所发出的光向驱动电路基板50的相反侧出射。此外在下面,作为驱动电路基板50的材料,虽记载了关于采用单晶硅的情况,但也可以是形成了多结晶硅TFT、IGZO-TFT的玻璃基板、塑料基板。
也可以在微型发光元件100的光的出射侧配置波长转换层(wavelengthconversion layer)、光扩散层(light diffusion layer)、彩色滤光片以及微型透镜等,但与本发明没有直接关系,因此在图中没有记载。
驱动电路基板50由微型发光元件驱动电路(micro light element drivecircuit)、行选择电路(row selection circuit)、列信号输出电路(column signaloutput circuit)、图像处理电路(image processing circuit)以及输入输出电路(input/output circuit)等构成。微型发光元件驱动电路控制供给至各微型发光元件100的电流。此外,行选择电路选择配置成二维矩阵状的微型发光元件100的各行。此外,列信号输出电路向微型发光元件100的各列输出发光信号。此外,图像处理电路基于输入信号计算发光信号。
驱动电路基板50的结合面侧的表面配置有用于与微型发光元件100连接的P侧电极51(P-drive electrode)(第二驱动电极)以及N侧电极52(N-drive electrode)(第一驱动电极)。
一般而言,驱动电路基板50是形成了LSI(Large-Scale Integrated circuit)的硅基板(半导体基板),能够以公知的技术制造,因此关于其功能以及构成不进行详细说明。
并且,沿着微型发光元件100的基板面的剖面可以采用矩形、多边形、圆形、以及椭圆形等各种平面形状。沿着基板面的方向的最大长度假设在60μm以下。
此外,假设图像显示元件200在像素区域1集成了3千个以上的微型发光元件100。
微型发光元件100作为发光体(light emission portion),包含化合物半导体14,一般而言依此顺序分别层叠有N侧层(N-side layer)11(第一导电层)、发光层(lightemission layer)12、以及P侧层(P-side layer)13(第二导电层)。
化合物半导体14例如,在以紫外至绿色为止的波段发光的微型LED元件中,为氮化物半导体(AlInGaN系)。此外,化合物半导体14在以黄绿色至红色为止的波段发光的情况下为AlInGaP系。进一步地,化合物半导体14在以红色至红外为止的波段下为AlGaAs系、GaAs系。
在下面,关于构成微型发光元件100的化合物半导体14,专门说明将N侧层配置于光出射侧的构成。然而,化合物半导体14可以是将P侧层13配置在光出射侧构成。
N侧层11、发光层12、以及P侧层13中的每一个通常优选为非单层并包含多层,但由于与本发明没有直接关系,因此各层的具体的结构没有记载。通常而言,发光层被N型层(N-type layer)与P型层(P-type layer)所夹,N型层、P型层为非掺杂层、或视情况也有可能是包含具有导电性相反的掺杂的层的情况,在下面记载为N侧层以及P侧层。
〔图像显示元件200的细节〕
如图1所示,图像显示元件200是发光的微型发光元件100以结合面(用粗的虚线表示)贴合至驱动电路基板50的构成。微型发光元件100中,发光层12被分割槽(isolationtrench)15分割。在像素区域1中的残留了发光层12的区域内配置有与P侧层13连接的P电极(P-electrode)19P(第二电极)。此外,像素区域1中的分割槽15的区域(分割区域(isolation region))内配置有与N侧层11连接的N电极(N-electrode)19N(第一电极)。
P电极19P与N电极19N如后述,经由同一工序而被同时地形成,因此形状、大小以及深度不同,但作为材料,由同结构的布线材料(wiring material)而构成。通常布线材料具有由阻挡金属层(burrier metal layer)、主导电层(conductive layer)、罩层(caplayer)等的多层构成的层叠结构,但P电极19P与N电极19N具有相同的层叠结构。即,图像显示元件200的微型发光元件100侧由单一布线层构成。
在本实施方式的构成中,利用与N侧层11欧姆连接的金属材料构成P电极19P与N电极19N,因此与P侧层13的欧姆连接能够经由P电极层(P-electrode layer)10来进行。P电极层10在例如化合物半导体14是氮化物半导体的情况下,为透明电极即ITO(Indium-Tin-Oxide、氧化铟锡)、钯(Pd)等的良导体。
微型发光元件100的分割槽15埋入保护膜(protection layer)17,且保护膜17的结合面侧的表面(第二面)平坦(flat)。P电极19P与N电极19N形成在结合面侧,其表面构成为与保护膜17的表面几乎相同高度的平面。
此外,驱动电路基板50侧的P侧电极51的表面与N侧电极52的表面高于绝缘膜(insulating layer)55的表面地构成。P电极19P以及N电极19N分别与驱动电路基板50侧的P侧电极51以及N侧电极52连接。
P电极19P与P侧电极51的界面、以及N电极19N与N侧电极52的界面排列有纳米尺寸的金属纳米粒子30。驱动电路基板50与微型发光元件100之间填埋有光固化树脂31。P电极19P与P侧电极51、或者N电极19N与N侧电极52经由大量的金属纳米粒子30而接触,并且,通过光固化树脂的收缩,驱动电路基板50与微型发光元件100紧密接触,因此能够实现良好的电连接。金属纳米粒子30的材质为钯(Pd),金(Au),铂(Pt),镍(Ni),铝(Al)等。光固化树脂是通过紫外线、近紫外线的照射而产生聚合反应并固化的树脂,可以是环氧树脂类、聚氨酯类、丙烯酸类、有机硅类等的丙烯酸酯自由基聚合型,也可以是环氧类的阳离子聚合型。
这样,P电极19P与P侧电极51、或是N电极19N与N侧电极52由金属纳米粒子30电连接,因此P电极19P以及N电极19N的表面层、和P侧电极51以及N侧电极52的表面层也可以为不同种材料。
〔微型发光元件100的概要〕
微型发光元件100若从结合面侧观察,则一般而言配置成二维阵列状。如图2的(b)所示,微型发光元件100的中央部配置有P电极19P,边界部的分割区域配置有N电极19N。如图2的(a)所示,在N电极19N的下部存在分割槽15。此外,图1是表示图2的(b)的A-A的剖面。此外,图2的(a)表示形成分割槽15后(图3的(b)的状态)的表面。进一步地,图2的(b)示出形成P电极19P以及N电极19N后(图3的(e)的状态)的表面。然而,省略了保护膜17。
〔微型发光元件100的制造方法〕
接着,使用图3说明微型发光元件100的制造工序。如图3的(a)所示,在生长基板9上依次层叠由N侧层11、发光层12以及P侧层13构成的化合物半导体,进而沉积P电极层10。生长基板9例如是蓝宝石基板。生长基板9优选对于紫外线、近紫外线而言透明的基板。
接着,如图3的(b)所示,蚀刻P电极层10、P侧层13、发光层12以及N侧层11的一部分,并形成分割槽15。此时,包含发光层12的部分成为台面16。
如图2的(a)所示,分割槽15被以等间隔配置在纵、横方向上,台面16成为四角锥台的形状。然而,台面16的形状不限于四角锥台,也可以是圆锥台、或其他多边形锥台。
台面16的侧壁优选相对于发光层12所形成的面倾斜45度±10度。从发光层12发出光之中,向与发光层12平行方向前进光的比例最多。因此,通过使这样的光向光出射面的方向反射,能够提高微型发光元件100的光提取效率。
在台面16的侧壁垂直的情况下,向水平方向出射的光反复反射,而不被出射至外部。若台面16的侧壁的倾斜从45度开始增大,则向光出射面入射时的入射角度变得过大,在光出射面产生全反射,还是不被出射至外部。
接着,如图3的(c)所示,沉积保护膜17,并对表面进行CMP研磨(Chemical-Mechanical-Polishing)而变平坦。保护膜17为绝缘膜,例如,SiO2、SiN、SiON、或是这些膜的层叠膜。保护膜17的成膜能够使用CVD法(Chemical Vapor Deposition、化学的气相成长法)、溅射法以及涂布等各种成膜技术。
接着,如图3的(d)所示,在台面16上形成P槽(P-groove)18P,并在分割槽15上形成N槽(N-groove)18N。P槽18P是孔形状,并到达至P电极层10。N槽18N是沿着纵横两个方向延伸的槽(channel)状,并到达至分割槽15的底部的N侧层11。
进一步地,如图3的(e)所示,利用金属镶嵌(Damascene)法,用金属膜填埋P槽18P以及N槽18N,并形成P电极19P以及N电极19N。金属膜是例如,钽(Ta)、钨(W)和氮化钛(TiN)等的阻挡膜与铜的组合。也可以是金或镍、铝合金等、和对应的阻挡膜的组合。在金属镶嵌法中,向具有槽的衬底结构沉积金属薄膜,并进行CMP研磨,由此能够在槽内残留金属薄膜,表面变得平坦。
在此,金属镶嵌法是指LSI的金属布线形成法之一,是将镀金技术与剥离法合用的薄膜形成技术。向绝缘层填埋微细的金属布线层的镶嵌(damascene)的手法被称为金属镶嵌法。在着眼于铜(Cu)布线的方法中,层间绝缘膜中形成布线形状的槽,并埋入铜等的金属。布线法有二,一个成为「单金属镶嵌布线法」,是在连接孔形成了金属的连接器插头后形成布线槽的方法。另一个称为「双金属镶嵌布线法」,是在形成了连接孔以及布线槽后,立即埋入金属的方法。金属镶嵌法与使多层布线层平坦的CMP技术组合来使用。图3的工序为单金属镶嵌法。
如上述那样,在台面16上配置P电极19P,在分割槽15上配置N电极19N,P电极19P以及N电极19N一同配置在成为结合面的表面(同一平面上),其表面由相同材料平坦地构成。
本实施方式的构成中,布线层构成有一层,并且,能够在分割槽15与台面16的形成、和P槽18P与N槽18N的形成的两个阶段的光刻工序中形成。因此,能够以非常简略的制造工序制作微型发光元件100,并削减设备投资,能够大幅度地降低制造成本。
〔图像显示元件200的制造方法〕
接着,使用图4说明图像显示元件200的制造工序。如图4的(a)所示,微型发光元件100经过图3的工序而形成。接着,如图4的(b)所示,在微型发光元件100的表面上排列金属纳米粒子30。金属纳米粒子30是例如钯。
钯的纳米粒子能够通过利用嵌段共聚物的自组装(日本国专利5875124参照)而形成。利用嵌段共聚物的自组装的方法之一,例如,(i)将作为嵌段共聚物的一种的聚苯乙烯-嵌段-聚(2-乙烯基吡啶)(polystyrene-block-poly(2-vinylpyridine))旋涂至微型发光元件100,(ii)将旋涂膜浸于四氯钯酸钠(Na2PdCl4)水溶液,使钯离子选择性地析出至聚苯乙烯-嵌段-聚(2-乙烯基吡啶)内的2-乙烯基吡啶(2-vinylpyridine)核,(iii)经由等离子处理去除聚苯乙烯-嵌段-聚(2-乙烯基吡啶)。在这个方法中,使数十nm尺寸的钯纳米粒子能够以100nm至300nm左右的间隔析出。
由于用于形成这样的金属纳米粒子30的嵌段共聚物的厚度极薄,因此在具有大的凹凸的平面上难以均匀地形成。因此,形成金属纳米粒子30的电极面必须平坦。在本实施方式中,微型发光元件100的表面平坦形成,满足这个条件。
此外,如图4的(c)所示,制造驱动电路基板50。驱动电路基板50例如,在单晶硅基板(晶圆)上通过通常的CMOS(Complementary metal-oxide semiconductor)工艺形成。驱动电路基板50侧的P侧电极51的表面与N侧电极52的表面高于绝缘膜55的表面地构成。构成P侧电极51与N侧电极52的布线材料为例如铜布线、铝合金。在铝合金的情况下,由于通过干法蚀刻技术加工,因此很容易形成图4的(c)的结构。在铜布线的情况下,由于利用金属镶嵌法而形成,因此表面为平坦,因此需要挖掘周边的绝缘膜层的额外工序。即,如图4的(c)所示,驱动电路基板50的结合面侧的表面的凸部为构成P侧电极51、N侧电极52的电极,凹部为所述电极间的绝缘膜55的露出部。
在此,驱动电路基板50优选为晶圆状态,微型发光元件100优选以图像显示元件200为单位被单片化。这种被单片化的微型发光元件100的集合体称为发光元件单元(lightemission unit)101。
接着,如图4的(d)所示,在排列了驱动电路基板50的硅基板上配置发光元件单元101。在此阶段中,在驱动电路基板50的结合面侧表面与发光元件单元101的结合面侧表面之间做成空隙33。接着,如图4的(e)所示,通过向界面注入光固化树脂,从而以光固化树脂31填埋空隙33。通过以发光元件单元为单位而连接,能够缩短光固化树脂遍布于整体的时间,且能够缩短结合时间。经历时间,能够结合晶圆彼此。
为了使光固化树脂31遍布于驱动电路基板50与发光元件单元101之间,在两者之间需要空间。难以在短时间内使光固化树脂31遍布以金属纳米粒子30的高度规定的空间内。由于使金属纳米粒子30附着的发光元件单元101侧的结合面为平坦,因此为了形成充足的空隙33,有必要在驱动电路基板50侧设置凹凸。这就是将P侧电极51、N侧电极52设为凸形状的理由。
接着,如图4的(f)所示,从生长基板9一侧,进行用于固化树脂的光照射,使光固化树脂31固化。生长基板9如硅基板那样,在不透射光的情况下,若不将生长基板9剥离,则无法光固化,因此生长基板9优选能够使用于光固化的光透射。通过进行光固化,驱动电路基板50与微型发光元件100紧密连接,因此接着进行的生长基板剥离工程(图4的(g))变得容易。生长基板9的剥离能够由激光剥离法等实现。在生长基板9的剥离后,通过加热,可以进一步推进光固化树脂31的聚合,进一步加强电连接。在此时,由于生长基板9被剥离,因此,因热膨胀系数差而产生的热应力被大幅度地缓和。
即使将微型发光元件100的P电极19P以及N电极19N通过金属纳米粒子30分别向驱动电路基板50的P侧电极51和N侧电极52压接,也不能充分降低连接电阻。然而,不升温,而利用光照射使光固化树脂31固化,能够产生大的收缩应力,并降低连接电阻。因此,即使对于热膨胀系数大幅不同的、驱动电路基板50与微型发光元件100而言,也能够不担心电极的位置偏移而进行连接。
〔效果〕
接着,图5的(a)中示出图像显示元件200的俯视图。在图像显示元件200之内、发光并实际上显示图像的部分为像素区域1。此前的说明是主要以像素区域1为对象的说明。
图像显示元件200在像素区域1以外具有不发光的区域即虚设区域2、多个外部连接区域3、将图像显示元件200分离为单个的切割部4等。在虚设区域2中,驱动电路基板50中配置有微型发光元件驱动电路以外的、行选择电路、列信号输出电路、图像处理电路以及输入输出电路等的电路。
贴附发光元件单元101以覆盖像素区域1。像素区域1上的发光元件单元101中虽配置有图1所示的微型发光元件100,但像素区域1的外侧有必要配置虚设元件110、基板侧虚设电极53。这些结构是用于降低光固化树脂31的向发光元件单元101外的漏出量的结构。例如,在从图5的(a)的(A)方向向驱动电路基板50与发光元件单元101之间注入光固化树脂31的情况下,若在(B)、(C)方向上光固化树脂31大量漏出,则覆盖外部连接区域3并难以去除。另一方面,如(D)方向那样,关于没有外部连接区域3的部分,些许漏出没有问题。此外,若减小驱动电路基板50与发光元件单元101之间的空隙,则需要用于使光固化树脂31遍及整体的时间,工序时间变长,这是不利的。在此,像素区域1的外周部需要根据方向而调整空隙的大小。即,被设置为虚设区域2的、靠近外部连接区域3的边的空隙小,且远离外部连接区域3的边的空隙大。
在本构成中,发光元件单元101的结合面平坦,因此空隙的大小根据驱动电路基板50侧的基板侧虚设电极53的长度而调整。在减小空隙的情况下,如图5的(b)那样地增长基板侧虚设电极53,在增大空隙的情况下,如图5的(c)那样地缩短基板侧虚设电极53即可。在此,上述空隙是被光固化树脂31填埋的部分。如此,在像素区域1的外周部配置用于调整空隙的大小的基板侧虚设电极53,并配置与其成对的虚设元件110,能够控制光固化树脂31的漏出量,容易实现外部连接区域3内的电连接。即,在本构成中,来自靠近外部连接区域3的像素区域的光固化树脂的漏出量能够减少得少于来自靠近外部连接区域3的像素区域的光固化树脂的漏出量。
关于发光元件单元101的外周的虚设元件110,也能够将发光元件单元101作为在驱动电路基板50上贴合时的暂时固定区域而使用。在使光固化树脂31均匀地遍及的期间,将发光元件单元101保持相对驱动电路基板50按压的状态,使粘合剂的吞吐量降低并非优选的。在此,例如,从(B)侧与(C)侧注入光固化树脂31,在向虚设元件110之下浸透的阶段中,进行光照射,从而在虚设元件110部分,将发光元件单元101固定于驱动电路基板50。只要光固化树脂31覆盖虚设元件110所需要的时间与浸透至发光元件单元整体的时间相比短,就能够提高粘合剂的吞吐量。在贴合了多个发光元件单元101后,从(A)侧注入光固化树脂31,并在遍及发光元件单元101整体后,进行光照射。这些工序对多个发光元件单元101而言能够并行地实行,因此即使花费些许时间,但能够实现高的生产性。在这种情况下,在(B)、(C)侧,基板侧虚设电极53形成的空隙大也可以。在从(B)、(C)侧注入光固化树脂31时,由于需要使少量的光固化树脂在短时间内向虚设元件110下浸透,因此空隙优选大的空隙。在从(A)侧注入光固化树脂31时,首先所注入的树脂固化,堵塞(B)、(C)侧,因此光固化树脂31没有向(B)、(C)侧漏出。另一方面,在(D)侧,为了使光固化树脂31的浸透均匀,例如,能够减小浸透速度快的中央部的、基板侧虚设电极53所形成的空隙,朝向靠近(B)、(C)侧的端部地逐渐加宽空隙。即,虚设区域2具有中央部的空隙小且周边部的空隙大的边。
如上述那样,像素区域1的外周优选配置有用于将发光元件单元101暂时固定、光固化树脂31的漏出的降低、或使光浸透树脂31的浸透均匀等的虚设元件110。进一步地,优选在像素区域1的外周配置用于控制发光元件单元101与驱动电路基板50之间的空隙的基板侧虚设电极53。
〔第一实施方式的变形例〕
在本第一实施方式中,微型发光元件100具有一种单色的显示元件。然而,如图6A的(a)所示,能够由蓝色副像素6、红色副像素7、以及绿色副像素8构成像素5,形成全彩的显示元件。各副像素分别具有单独的微型发光元件。各副像素分别也可以由分别发出蓝色光、红色光以及绿色光的微型发光元件构成,也可以使发出蓝色光的微型发光元件与波长转换层组合,使各副像素进行红色发光或是绿色发光。
图6A的(a)中,由分割槽15包围各副像素的周围,在分割槽15上配置有N电极19N。然而,如图6A的(b)所示,虽用分割槽15包围各副像素的周围,但也可以以覆盖像素5的周围的方式配置N电极19N。在这种情况下,由于不需要在像素5内的副像素之间配置N电极19N,因此能够缩窄副像素之间的分割槽15。其结果是,通过加宽副像素的台面16的宽度,能够增大发光层12的面积,降低流向发光层12的电流密度,使发光效率提高。
进一步地,如图6A的(c)所示,可以将N电极19N配置在仅像素5的边界的一个方向,如图6A的(d)所示,也可以将N电极19N以点状配置在像素5的四个角。任一个都具有与图6A的(b)相同的效果,随着N电极19N的配置量变少,发光效率提高等的效果变大。如此,N电极19N虽被配置在分割槽15上,但不一定需要配置在分割槽15的整个区域。为了使在像素5之间的光输出偏差均匀,在像素5之间布线电阻需要为均匀的,因此N电极19N优选至少针对每个像素5地设置。因此,如图6A的(d)所示,最好是在像素5四个角配置N电极19N的构成。副像素的形状不限于图6A的(a)示出的形状,也可以是例如图6B的(a)所示的形状。
在此之前的例子中,P电极19P相对微型发光元件100配置一个,但不限定为一个。例如,如图6B的(b)所示,也可以配置P电极1 19P1与P电极2 19P2的两个。通过设置P电极119P1与P电极219P2,一个为导通不良时,能够实现以另一个替代的冗余功能。并且,在此,冗余功能是指,以防备万一系统的一部分发生任何故障的情况,从平时预先配置并运用备份装置作为备用,以便在故障发生后也继续维持系统整体的功能。
此外,如图6B的(c)所示,P电极层也分割成P电极1 10-1和P电极2 10-2,能够将微型发光元件100实质性地分割成两个。在P电极1 19P1侧为不良时,通过使用P电极2 19P2,不仅电极的导通不良,也能够对微型发光元件100实现冗余功能。
为了实现这个冗余功能,需要在驱动电路基板50侧,针对每个微型发光元件100存储不良的有无,使每个微型发光元件100具备选择工作时为正常的一侧的P电极的功能,会造成成本增加,但一般而言,冗余所带来的产量提高的成本削减效果大,这样的冗余功能有效。
并且,在此时,由于P电极层10的图案与台面16的图案不同,光刻工序有可能增加一个工序。然而,由工序增加带来的成本上涨、以及由冗余功能带来的产量提高的成本降低的权衡,能够确定优先P电极的分割和P电极层的分割的哪一个。如上所述,P电极被配置在具有发光层12的台面16上,但不一定限定为一个,也可以是配置多个的情况。
如上述那样,缩小微型发光元件100的电极并高密度地配置不仅是像素的微小化,从各方面来说还需要用于全彩化的副像素的形成、用于产量提高的冗余功能的追加等。对于这样的电极尺寸的微小化而言,在各电极形成凸点将逐渐变得困难。对此,如本发明那样配置自组装的金属纳米粒子的结构不需要担心电极之间短路,并能够在各电极上设置大量凸部。
〔第二实施方式〕
以下,说明本发明的其他实施方式。
如图7的(a)所示,本实施方式的图像显示元件200a与所述第一实施方式的图像显示元件200的不同之处在于,驱动电路基板50a侧的结合面平坦,微型发光元件100a的结合面侧不平坦,而被分离成单个,以及在微型发光元件100a的结合面侧具有P电极19P,在光照射面侧具有共用N电极40。
〔图像显示元件200a的概要〕
如图7的(a)所示,图像显示元件200a是发出光的微型发光元件100a以结合面(用粗的虚线表示)贴合于驱动电路基板50a的构成。微型发光元件100a通过分割槽15而发光层12被分割,进一步地通过分离槽(separation trench)20被完全分割成每一个微型发光元件100a。在像素区域1中的残留了发光层12的区域内配置有与P侧层13连接的P电极19P(第二电极)。此外,如图7的(b)所示,与N侧层11连接的共用N电极(common N-electrode)40在像素区域1的外侧与N电极19N(第一电极)连接。
驱动电路基板50a侧的P侧电极51的表面与绝缘膜55的表面几乎平坦地构成。P电极19P与驱动电路基板50a侧的P侧电极51连接。
在P电极19P与P侧电极51的界面排列有纳米尺寸的金属纳米粒子30。驱动电路基板50a与微型发光元件100a之间填埋有光固化树脂31。P电极19P与P侧电极51、或者N电极19N与N侧电极52经由大量的金属纳米粒子30而接触,并且,通过光固化树脂的收缩,驱动电路基板50a与微型发光元件100a紧密接触,因此能够实现良好的电连接。
在本构成中,驱动电路基板50a的结合面平坦,因此空隙33的大小根据分离槽20而确定微型发光元件100a的结合面侧的表面的凸部即构成P电极19P的电极、以及凹部即位于分割槽15部的保护膜17露出部。即,凹部为分割槽15部。具体而言,根据发光元件单元101a侧的P电极19P的长度与分离槽20的宽度而调整。
在减小空隙33时,只要如图7的(c)那样地,增长虚设元件110a的P电极19P,并减少分离槽20的配置即可。在增大空隙的情况下,相反地,只要将分离槽20紧密地配置,并缩短P电极19P即可。即,只要增长分割槽15部分的长度即可。如此,与第一实施方式同样地,通过在像素区域1的外周部配置虚设元件110a,能够用于将发光元件单元101a暂时固定。此外,通过控制虚设元件110a的空隙的大小,与第一实施方式同样地,能够进行光固化树脂31的漏出的降低、或使光浸透树脂31的浸透均匀。
〔微型发光元件100a的制造方法〕
接着,使用图8说明微型发光元件100a的制造工序。示出虚设元件110a的一部分,左侧为其所包含的像素部,右侧为其所包含的N电极。微型发光元件100a的制造工序经由与图3的(a)、(b)、(c)相同的工序,因此省略此部分。因此,如图8的(a)所示,在保护膜17被沉积在台面16上之后,如图8的(b)所示,在台面16上形成P槽18P。P槽18P是孔形状,并到达至P电极层10。虚设元件区域中,N槽18N被形成于分割部15的底部,并到达至N侧层11。进一步地,如图8的(c)所示,利用金属镶嵌法,用金属膜填埋P槽18P以及N槽18N,并形成P电极19P以及N电极19N。
接着,如图8的(d)所示,通过蚀刻保护膜17的表面,使P电极19P与N电极19N的上部露出。本蚀刻可以是干法蚀刻或湿法蚀刻。进一步地如图8的(e)所示,蚀刻保护膜17与化合物半导体层14,从而形成分离槽20。分离槽20优选将微型发光元件100a分离成单个。通过分离,能够降低微型发光元件100a之间的光泄露,因此能够降低由于光泄露而产生的显示图像的对比度低、混色。
如微型发光元件100a那样,在结合面只具有一个电极的发光元件在与驱动电路基板50a贴合后,有必要在光照射面形成另一个电极,但具有如下优点:能够形成达到在结合面上没有空间并列设置P电极与N电极的空间的程度的微细的像素尺寸。
如图8的(e)所示,分离槽20优选到达至生长基板9,但也可以停留在化合物半导体层14。化合物半导体层14的残留膜厚越薄,光泄露越被降低,因此从光泄露的降低的观点出发,化合物半导体层14的残留膜厚越薄越好。然而,通过残留薄的化合物半导体层14,能够使微型发光元件100a的光出射面均匀且平坦,因此从能够降低共用N电极40的电阻,并降低出射光的散射的观点出发是有利的。
〔图像显示元件200a的制造方法〕
接着,使用图9说明图像显示元件200a的制造工序。如图9的(a)所示,微型发光元件100a经过图8的工序而形成。接着,如图9的(b)所示,制造驱动电路基板50a。驱动电路基板50a例如,在单晶硅基板(晶圆)上通过通常的CMOS(Complementary metal-oxidesemiconductor)工艺形成。驱动电路基板50a侧的P侧电极51的表面与N侧电极52的表面与绝缘膜55的表面平坦地构成。构成P侧电极51的表面与N侧电极52的布线材料为例如铜布线。在铜布线的情况下,由于利用金属镶嵌法而形成,因此表面平坦,能够容易制造图9的(b)的结构。
接着,如图9的(c)所示,在驱动电路基板50a的表面上利用与第一实施方式同样的方法来排列钯的纳米粒子。在第一实施方式中如图4(b)所示,金属纳米粒子被配置在微型发光元件100的结合面,但在本实施方式中金属纳米粒子被配置在驱动电路基板50a的结合面。
在此,驱动电路基板50a优选为晶圆状态,微型发光元件100a优选以图像显示元件200a为单位被单片化。这种被单片化的微型发光元件100a的集合体称为发光元件单元101。
接着,如图9的(d)所示,在排列了驱动电路基板50a的硅基板上配置发光元件单元101a,如图9的(e)所示,向界面注入光固化树脂。在此光固化树脂是通过紫外线、近紫外线的照射,产生聚合反应并固化的树脂。通过以发光元件单元为单位而连接,能够缩短光固化树脂遍布于整体的时间,且能够缩短结合时间。经历时间,也能够进行晶圆彼此的结合。
接着,如图9的(f)所示,从生长基板9一侧,进行用于固化树脂的光照射,使光固化树脂31固化。生长基板9如硅基板那样,在不透射光的情况下,若不将生长基板9剥离,则无法光固化,生长基板9优选能够透射使光固化树脂31固化的光。通过进行光固化,驱动电路基板50a与微型发光元件100a紧密连接,因此接着进行的生长基板剥离工程(图9的(g))变得容易。生长基板9的剥离能够由激光剥离法等实现。在生长基板9的剥离后,通过加热,可以进一步推进光固化树脂31的聚合,进一步加强电连接。在此时,由于生长基板9被剥离,因此,因热膨胀系数差而产生的热应力被大幅度地缓和。
接着,如图9的(h)所示,在微型发光元件100a的光出射面侧形成共用N电极40。共用N电极40例如,是透明导电膜即ITO(Indium Tin Oxide:氧化铟锡)薄膜。
根据本构成,也能够得到与上述第一实施方式同样的效果。
〔第三实施方式〕
以下,说明本发明的另一其他实施方式。
如图10的(a)所示,本实施方式与所述第一实施方式的图像显示元件200的不同之处在于,在本实施方式的图像显示元件200b中,驱动电路基板50b侧的结合面与微型发光元件100b的结合面侧不都平坦,微型发光元件100b被分离为单个。
〔图像显示元件200b的概要〕
如图10的(a)所示,图像显示元件200b是发光的微型发光元件100b以接合面(以粗的虚线表示)贴合在驱动电路基板50b上的构成。微型发光元件100b通过分割槽15而发光层12被分割,进一步地通过分离槽20被分割成每一个微型发光元件100b。
P电极19P与N电极19N如后述,经由同一工序而被同时地形成,因此形状、大小以及深度不同,但作为材料,由同结构的布线材料而构成。普通布线材料具有由阻挡金属层、主导电层、罩层等的多层构成的层叠结构,但P电极19P与N电极19N具有相同的层叠结构。即,图像显示元件200b的微型发光元件100侧由单一的布线层构成。
在本实施方式的构成中,利用与N侧层11欧姆连接的金属材料构成P电极19P与N电极19N,因此与P侧层13的欧姆连接能够经由P电极层10来进行。P电极层10在例如化合物半导体14是氮化物半导体的情况下,为透明电极即ITO(Indium-Tin-Oxide、氧化铟锡)、钯(Pd)等的良导体。
微型发光元件100b的分割槽15被保护膜17覆盖,但没有被埋入保护膜17。P电极19P与N电极19N是指,形成于结合面侧,并在残留了微型发光元件100b的发光层12的区域内配置有与P侧层13连接的P电极19P(第二电极)、以及与N侧层11连接的N电极19N。
驱动电路基板50b侧的P侧电极51的表面与N侧电极52的表面高于绝缘膜55的表面地构成。P电极19P以及N电极19N分别与驱动电路基板50侧的P侧电极51以及N侧电极52连接。
两个电极的界面排列有纳米尺寸的金属纳米粒子30。驱动电路基板50b与微型发光元件100b之间填埋有光固化树脂31。P电极19P与P侧电极51、或者N电极19N与N侧电极52经由大量的金属纳米粒子30而接触,并且,通过光固化树脂的收缩,驱动电路基板50b与微型发光元件100b紧密接触,因此能够实现良好的电连接。
这样,P电极19P与P侧电极51、或是N电极19N与N侧电极52由金属纳米粒子30电连接,因此P电极19P以及N电极19N的表面层、和P侧电极51以及N侧电极52的表面层也可以为不同种材料。
在本构成中,驱动电路基板50b的结合面的电极高于绝缘膜55地形成,因此能够在像素区域1的外侧配置基板侧虚设电极53,并控制空隙的大小。即,驱动电路基板50b的结合面侧表面的凸部为P侧电极51、N侧电极52、虚设电极53等的电极,凹部为绝缘膜55的露出部。此外,还可以根据发光元件单元101b侧的P电极19P的长度与分离槽20的宽度调整空隙的大小。即,发光元件单元101b侧的结合侧表面的凸部为P电极19P、N电极19N的电极,凹部为包含分离槽20的分割槽15部。在减小空隙时,只要如图10的(b)那样地,增长虚设元件110b的P电极19P,并减少分离槽20的配置即可。同时,可以配置长的基板侧虚设电极53。在增大空隙的情况下,相反地,只要将分离槽20紧密地配置,并缩短P电极19P即可。也可以配置短的基板侧虚设电极53。如此,与第一实施方式同样地,通过在像素区域1的外周部配置虚设元件110b,能够用于将发光元件单元101b暂时固定。此外,通过控制虚设元件110b的空隙的大小,与第一实施方式同样地,能够进行光固化树脂31的漏出的降低、或使光浸透树脂31的浸透均匀。
〔微型发光元件100b的制造方法〕
接着,使用图1说明微型发光元件100b的制造工序。微型发光元件100b的制造工序经由与图3的(a)、(b)相同的工序,因此省略此部分。如图11的(a)所示,虽沉积保护膜17b,但无需如第一实施方式那样完全埋入分割槽15,因此只要是薄的膜即可。接着,如图11的(b)所示,在台面16上形成P接触孔21P、以及在分割槽15的底部形成N接触孔21N。P接触孔21P为孔状,并到达至P电极层10,N接触孔21N也为孔状,并到达至N侧层11。进一步地,如图11的(c)所示,利用剥离法形成P电极19bP以及N电极19bN。电极材料例如以金(Au)为主布线材料,并在其下配置有成为密着层、阻挡层的镍(Ni)、白金(Pt)。
接着,如图11(d)所示,通过蚀刻分割槽15的保护膜17b与化合物半导体层14,从而形成分离槽20。分离槽20优选将微型发光元件100b分离为单个。分离槽20的作用与第二实施方式相同。
本制造工序接近以往类型的LED的制造工序,并且简便,在微型发光元件100b比较大的情况下有效。
〔图像显示元件200b的制造方法〕
接着,使用图12说明图像显示元件200b的制造工序。此外,如图12的(a)所示,制造驱动电路基板50b。驱动电路基板50b例如,在单晶硅基板(晶圆)上通过通常的CMOS(Complementary metal-oxide semiconductor)工艺形成。驱动电路基板50b侧的P侧电极51的表面与N侧电极52的表面高于绝缘膜55的表面地构成。构成P侧电极51的表面与N侧电极52的布线材料为例如铝合金布线。
在这样的凹凸的某一基板表面上难以直接形成金属纳米粒子,因此暂时使表面平坦,并形成金属纳米粒子,在其后需要将除了电极部以外去除。
首先,如图12的(b)所示,在P侧电极51的表面与N侧电极52之间形成平坦化层32。接着,如图12的(c)所示,利用与第一实施方式同样的方法来排列钯的纳米粒子。之后,如图12的(d)所示,去除平坦化层32。平坦化层32是例如树脂层,能够以涂布、回蚀进行平坦化,并利用溶剂溶解去除。
在此,驱动电路基板50b优选为晶圆状态,微型发光元件100b优选以图像显示元件200b为单位被单片化。这种被单片化的微型发光元件100b的集合体是发光元件单元101b。
接着,如图12的(e)所示,在排列了驱动电路基板50b的硅基板上配置发光元件单元101b,如图12的(f)所示,向界面注入光固化树脂。
接着,如图12的(g)所示,从生长基板9一侧,进行用于固化树脂的光照射,使光固化树脂31固化。生长基板9如硅基板那样,在不透射光的情况下,若不将生长基板9剥离,则光固化无法进行,生长基板9优选能够透射固化的光。通过进行光固化,驱动电路基板50b与微型发光元件100b紧密连接,因此接着进行的生长基板剥离工程(图12的(h))变得容易。生长基板9的剥离能够由激光剥离法等实现。在生长基板9的剥离后,通过加热,可以进一步推进光固化树脂31的聚合,进一步加强电连接。在此时,由于生长基板9被剥离,因此因热膨胀系数差而产生的热应力被大幅度地缓和。
根据本构成,也能够得到与上述第一实施方式同样的效果。
〔第四实施方式〕
以下,说明本发明的另一其他实施方式。
如图13的(c)所示,在本实施方式与所述第一实施方式的微型发光元件100的不同之处在于,在本实施方式的微型发光元件100c为VCSEL(垂直腔面发射激光器,VerticalCavity Surface Emitting LASER)类的微型激光元件。与微型LED元件相比,发光波长的光谱窄,可以进行指向性高的显示。
〔微型发光元件100c的制造方法〕
下面,参照图13说明微型发光元件100c的制造方法的一例。图13的(a)至图13的(e)分别表示微型发光元件100c的制造工序的剖视图。
如图13的(a)所示,通过在生长基板9上依次顺序沉积第一反射层42、N侧层11c、发光层12以及P侧层13而形成化合物半导体14c。第一反射层42是反射振荡波长的光的DBR(Distributed Bragg Reflector)。在使用氮化物半导体来发出蓝色光的情况下,第一反射层42能够通过重叠多层AlxGa(1-x)N层以及GaN层的对来形成。例如,包含20层的GaN层厚46nm、AlxGa(1-x)N层47nm的共93nm厚的GaN/AlGaN对,总厚为1.8μm左右。
在化合物半导体层14c之上,进一步地,沉积透明电极层44与第二反射层45。透明电极层44是ITO(铟·锡·氧化物)等的电极层,厚度为50nm至600nm左右。第二反射层45是由电介质多层膜构成的DBR。例如,TiO2薄膜(厚度36nm)与SiO2薄膜(厚度77nm)的对设为10层,整体厚为1.1μm左右。相对于蓝色光的第二反射层45的反射率高于第一反射层42的反射率。
如图13的(b)所示,在层叠了第二反射层45之后,利用光刻技术以及干法蚀刻技术而形成分割槽15。分割槽15蚀刻第二反射层45、透明电极44、P侧层13、发光层12、N侧层11的一部分。分割槽15的侧面如第一实施方式那样,不需要施加大的倾斜。这是由于激光元件在水平方向上不发光,因此不需要在垂直方向上反射。接着,如图13的(c)所示,用保护膜17填埋分割槽15,将表面设为平坦。进一步地,如图13的(d)所示,形成N槽18N与P槽18P。N槽18N蚀刻保护膜17来到达至分割槽15的底部的N侧层11c。P槽18P蚀刻保护膜17与第二反射层45而到达至透明电极44。接着,如图13的(e)所示,形成P电极19cP与N电极19N。在此,P电极19cP被形成在发光层之上,但对于发光层12存在的区域而言,优选配置在外周部而非其中心。这是由于P电极19cP贯通第二反射层45,因此阻碍激光元件的发光。
如上述那样,在发光层12上配置P电极19cP,在分割槽15上配置N电极19N,与P电极19cP、N电极19N一同配置在成为结合面的表面,其表面由相同材料平坦地构成。通过将微型发光元件100c与驱动电路基板(与所述第一实施方式的驱动电路基板50相同的构成)结合,能够与第一实施方式同样地构成图像显示元件。并且,能够实现与第一实施方式相同的效果。甚至,本实施方式相对于第一实施方式,能够达到缩窄发光波长的光谱宽度、指向性高之类的附加效果。
本发明不限于上述各实施方式,能在权利要求所示的范围中进行各种变更,将在不同的实施方式中分别公开的技术手段适当组合而得到的实施方式也包含于本发明的技术范围。而且,能够通过组合各实施方式分别公开的技术方法来形成新的技术特征。
附图标记说明
1 像素区域
2 虚设区域
3 外部连接区域
4 切割部
5 像素
6 蓝色副像素
7 红色副像素
8 绿色副像素
9 生长基板
10 P电极层
11、11c N侧层
12 发光层
13 P侧层
14、14c 化合物半导体
15 分割槽
16 台面
17、17b 保护膜
18P P槽
18N N槽
19P、19P1、19P2、19bP、19cP P电极
19N、19bN N电极
20 分离槽
21P P接触孔
21N N接触孔
30 金属纳米粒子
31 光固化树脂
32 平坦化层
40 共用N电极
42 第一反射层
44 透明电极层
45 第二反射层
50、50a、50b 驱动电路基板
51 P侧电极
52 N侧电极
53 基板侧虚设电极
55 绝缘膜
100、100a、100b、100c 微型发光元件
101、101a、101b 发光元件单元
110、110a、虚设元件
200、200a、200b 图像显示元件

Claims (20)

1.一种图像显示元件,其在内置有微型发光元件的驱动电路的驱动电路基板之上,连接了多个所述微型发光元件,所述微型发光元件在与所述驱动电路的结合面的相反侧具有光出射面,所述图像显示元件的特征在于,
在所述微型发光元件的结合面侧的表面与所述驱动电路基板的结合面侧的表面的至少一个表面中具有凹凸形状,
所述微型发光元件的电极与所述驱动电路的基板侧的电极经由金属纳米粒子连接,
所述微型发光元件的结合面侧的表面与所述驱动电路基板的结合面侧的表面之间所形成的空隙填充有光固化树脂。
2.根据权利要求1所述的图像显示元件,其特征在于,
所述微型发光元件的结合面侧的表面为平坦,所述驱动电路基板的结合面侧的表面具有凹凸形状。
3.根据权利要求2所述的图像显示元件,其特征在于,
所述驱动电路基板的结合面侧的表面的凸部是电极。
4.根据权利要求1所述的图像显示元件,其特征在于,
所述驱动电路基板的结合面侧的表面为平坦,所述微型发光元件的结合面侧的表面具有凹凸形状。
5.根据权利要求4所述的图像显示元件,其特征在于,
所述微型发光元件的结合面侧的表面的凸部是电极。
6.根据权利要求4所述的图像显示元件,其特征在于,
所述微型发光元件的结合面侧的表面的凹部是将所述微型发光元件的发光层分割的分割槽部。
7.根据权利要求1所述的图像显示元件,其特征在于,
所述微型发光元件的结合面侧的表面具有凹凸形状,所述驱动电路基板的结合面侧的表面也具有凹凸形状。
8.根据权利要求7所述的图像显示元件,其特征在于,
所述微型发光元件的结合面侧的表面的凸部为电极,凹部为分割所述微型发光元件的发光层的分割槽部,所述驱动电路基板的结合面侧的表面的凸部为电极。
9.根据权利要求1所述的图像显示元件,其特征在于,
所述金属纳米粒子配置在所述微型发光元件的结合面侧的表面。
10.根据权利要求1所述的图像显示元件,其特征在于,
所述金属纳米粒子配置在所述驱动电路基板的结合面侧的表面。
11.根据权利要求1所述的图像显示元件,其特征在于,
在所述图像显示元件的由发光的像素构成的像素区域的外周具有由与微型发光元件相同的材料构成的虚设元件、以及对应于所述虚设元件的虚设电极被配置在所述驱动电路基板上的虚设区域,所述虚设元件与所述驱动电路基板之间的空隙与所述像素区域不同。
12.根据权利要求11所述的图像显示元件,其特征在于,
所述虚设元件所具有的虚设电极与所述驱动电路的基板侧的虚设电极均比像素部长。
13.根据权利要求11所述的图像显示元件,其特征在于,
所述虚设元件所具有的分割槽部的长度比像素部长。
14.根据权利要求11所述的图像显示元件,其特征在于,
所述虚设元件与所述驱动电路基板之间的空隙的图案根据所述像素区域的边而不同。
15.根据权利要求11所述的图像显示元件,其特征在于,
设为:所述虚设区域的接近所述图像显示元件的外部连接区域的边的空隙小,所述虚设区域的远离所述外部连接区域的边的空隙大。
16.根据权利要求11所述的图像显示元件,其特征在于,
所述虚设区域的一边的中央部的空隙小,周边部的空隙大。
17.根据权利要求1所述的图像显示元件,其特征在于,
接近所述图像显示元件的外部连接区域的边的光固化树脂的漏出量比远离所述外部连接区域的边的光固化树脂的漏出量少。
18.一种图像显示元件的制造方法,其特征在于,包括:
在生长基板上形成由化合物半导体构成的微型发光元件的工序;
形成包含驱动电路的驱动电路基板的工序;
将金属纳米粒子排列在所述微型发光元件的结合面和驱动电路基板的结合面中的任一个的工序;
在所述驱动电路基板上配置所述微型发光元件的工序;
在所述驱动电路基板上将光固化树脂注入所述微型发光元件之间的工序;
向所述光固化树脂照射光并使其固化的工序;以及
剥离所述生长基板的工序。
19.根据权利要求18所述的图像显示元件的制造方法,其特征在于,
向所述光固化树脂照射光并使其固化的工序通过所述生长基板而进行。
20.根据权利要求18所述的图像显示元件的制造方法,其特征在于,
将所述微型发光元件配置在所述驱动电路基板上的工序包含向与所述微型发光元件同时形成的虚设元件部注入光固化树脂,并通过光照射固化的工序。
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CN112652253A (zh) * 2021-01-06 2021-04-13 Tcl华星光电技术有限公司 显示面板及其制作方法
CN113488502A (zh) * 2021-06-30 2021-10-08 上海天马微电子有限公司 一种显示面板及其制作方法和显示装置
CN114420720A (zh) * 2022-03-29 2022-04-29 季华实验室 一种MicroLED显示面板制作方法及显示面板

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