CN111668205B - 显示装置及显示装置的制造方法 - Google Patents

显示装置及显示装置的制造方法 Download PDF

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CN111668205B
CN111668205B CN202010511417.XA CN202010511417A CN111668205B CN 111668205 B CN111668205 B CN 111668205B CN 202010511417 A CN202010511417 A CN 202010511417A CN 111668205 B CN111668205 B CN 111668205B
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light
adhesive layer
substrate
emitting elements
emitting element
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CN111668205A (zh
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蓝伊奋
吴宗典
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AU Optronics Corp
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Abstract

一种显示装置及显示装置的制造方法。显示装置包括一基板、多个第一发光元件以及至少一个第二发光元件。第一发光元件排列于基板上。每一个第一发光元件背向基板的表面上具有多个第一电极。第二发光元件配置于基板上。第二发光元件背向基板的表面上具有多个第二电极。第二发光元件在基板上的正投影与第一发光元件在基板上的正投影部分重叠。

Description

显示装置及显示装置的制造方法
技术领域
本发明涉及一种装置及装置的制造方法，且特别涉及一种显示装置及显示装置的制造方法。
背景技术
发光元件阵列显示装置是由设置于基板上的阵列排列的多个发光元件构成。继承目前的发光元件的特性，发光元件阵列显示装置具有省电、高效率、高亮度及反应时间快等优点。但是，在制造显示装置时，批次转移发光元件至基板时常发生错位、倾斜或甚至遗漏发光元件的问题。过去的作法，需更换转移头来一一地移除有问题的发光元件并重新转移，但会耗费大量的工艺时间。
发明内容
本发明提供一种显示装置及显示装置的制造方法，可改善工艺成本过高的问题。
本发明的显示装置包括一基板、多个第一发光元件以及至少一个第二发光元件。第一发光元件排列于基板上。每一个第一发光元件背向基板的表面上具有多个第一电极。第二发光元件配置于基板上。第二发光元件背向基板的表面上具有多个第二电极。第二发光元件在基板上的正投影与第一发光元件在基板上的正投影部分重叠。
本发明的另一显示装置包括一基板、多个第一发光元件以及至少一个第二发光元件。第一发光元件排列于基板上。第二发光元件配置于基板上。第二发光元件电性独立。第二发光元件在基板上的正投影与第一发光元件在基板上的正投影部分重叠。
在本发明的一实施例中，第二发光元件位于第一发光元件与基板之间。
在本发明的一实施例中，显示装置还包括一粘着层。第一发光元件与第二发光元件通过粘着层固定于基板上，且粘着层的厚度大于一个第一发光元件的厚度与第二发光元件的厚度的总和。
在本发明的一实施例中，显示装置还包括多个岛状接垫。粘着层具有多个开口。各岛状接垫位于对应的一个开口内。各岛状接垫电性连接对应的一个第一电极。各岛状接垫的高度小于等于粘着层的厚度的一半。
在本发明的一实施例中，显示装置还包括一第一粘着层与一第二粘着层。第一粘着层位于基板与第二粘着层之间。第一发光元件与第二发光元件通过第一粘着层与第二粘着层固定于基板上，且第二发光元件位于第一粘着层与第二粘着层之间。
在本发明的一实施例中，显示装置还包括多个岛状接垫。第一粘着层具有多个第一开口。第二粘着层具有多个第二开口。各第一开口与对应的一个第二开口重叠。各岛状接垫位于对应的一个第一开口与对应的一个第二开口内。各岛状接垫电性连接对应的一个第一电极。各岛状接垫的高度小于等于第一粘着层的厚度与一个第一发光元件的厚度的总和。
本发明的显示装置的制造方法包括下列步骤。使用一转移头进行多次第一转移，以排列多个第一发光元件于一基板上。每次第一转移转移多个第一发光元件。进行检查并标记第一发光元件中的至少一个姿态不良者的位置。使用转移头对第一发光元件中的至少一个姿态不良者的位置进行一次第二转移，以将移转头在第二转移时涵盖的区域内原有的第一发光元件中的至少一个姿态不良者以新的第一发光元件覆盖。
在本发明的一实施例中，进行第一转移前，还包括形成一第一粘着层于基板上，第一转移转移第一发光元件于第一粘着层上。
在本发明的一实施例中，在进行检查之后与覆盖原有的第一发光元件之前，还包括在第一粘着层上形成一第二粘着层，第二粘着层至少覆盖第一发光元件中的至少一个姿态不良者。
基于上述，在本发明的显示装置及显示装置的制造方法中，不移除姿态不良的发光元件，而直接以新的发光元件将其覆盖，可缩短工艺时间而降低制造成本。
附图说明
图1A至图1F是依照本发明的一实施例的显示装置的制造方法的流程的剖面示意图。
图2A至图2C是依照本发明的另一实施例的显示装置的制造方法的部分流程的剖面示意图。
图3A至图3I是依照本发明的一实施例的显示装置的制造方法的接线流程的剖面示意图。
图4A与图4B是依照本发明的两种实施例的显示装置的局部剖面示意图。
图5是依照本发明的一实施例的显示装置的数种接垫的示意图。
图6是依照本发明的一实施例的显示装置的俯视图。
附图标记说明：
50：转移头
100,102,104,106：显示装置
110：基板
122：第一粘着层
124：第二粘着层
132：第一发光元件
132A：第一电极
134：第二发光元件
134A：第二电极
S12,S14：表面
P12,P14：正投影
T12,T14,T16：厚度
62,64：光刻胶层
O12,O14,O16,O18：开口
142：接垫
150：接线
144：岛状接垫
H12：高度
具体实施方式
图1A至图1F是依照本发明的一实施例的显示装置的制造方法的流程的剖面示意图。本实施例的显示装置的制造方法包括下列步骤。请参照图1A，首先提供一基板110。选择性地，基板110上可先形成有一第一粘着层122。
接着请参照图1B，使用一转移头50进行多次第一转移，以排列多个第一发光元件132于基板110上。当存在第一粘着层122时，第一转移转移第一发光元件132于第一粘着层122上，而第一粘着层122可提供适当的定位效果。每次第一转移转移多个第一发光元件132。在图1B中，仅示意地显示转移头50进行一次第一转移可涵盖的范围，而转移头50需要进行多次第一转移才能在整个基板上排列完第一发光元件132。举例来说，基板110上若需要排列8百万个第一发光元件132，而转移头50进行一次第一转移可转移4万个第一发光元件132，则需进行2百次第一转移才能在整个基板上排列完第一发光元件132。
接着请参照图1C，进行检查并标记第一发光元件132中的至少一个姿态不良者的位置。图1C中以虚线框表示第一发光元件132的正常位置。在图1C中，举例了一个第一发光元件132的位置产生了偏移，一个第一发光元件132的姿态倾斜，还有一个第一发光元件132并未成功从转移头50转移至基板110上。
接着使用转移头50对第一发光元件132中的至少一个姿态不良者的位置进行一次第二转移。图1D中显示转移头50上带有新的第一发光元件132，并且对准欲转移的位置。接着请参照图1E，在第二转移时将移转头50涵盖的区域内原有的第一发光元件132中的至少一个姿态不良者以新的第一发光元件132覆盖。本实施例中，是将移转头50涵盖的区域内所有原有的第一发光元件132都以新的第一发光元件132覆盖。最后，请参照图1F，将转移头50移开，就完成了显示装置100的制造。
从上述可知，在本实施例的显示装置的制造方法中，不论是第一转移或是第二转移，都是使用相同的转移头50，可节省更换转移头所需的工艺时间与成本。此外，在第二转移时，是一次将转移头50涵盖的区域内有问题的位置都覆盖新的第一发光元件132，而不是一颗一颗地转移，可缩短工艺时间。
在上述实施例中，进行第二转移时，是将移转头50涵盖的区域内全部原有的第一发光元件132都以新的第一发光元件132覆盖，如此可节省进行第二转移前选择性地拾取新的第一发光元件132所需的时间。但是，在其他实施例中，也可仅在有问题的位置覆盖新的第一发光元件132以节省材料成本，但仍在一次第二转移中将移转头50涵盖的区域内有问题的位置都覆盖新的第一发光元件132。另外，第二转移需要进行的次数可在进行检查并标记第一发光元件132中的至少一个姿态不良者的位置之后决定，例如是计算如何以最少次数的第二转移涵盖全部被标记的位置。在进行检查并标记前，并不会对第一发光元件132进行接线，因此并不是以点亮测试的方法来确认每个第一发光元件132是否为良品。取而代之的，是由检查设备以光学手段判断第一发光元件132的姿态是否良好。因此，第二转移时被覆盖的第一发光元件132并不会接线，而是呈现电性独立的状态，也就是呈现浮置(floating)的状态。
请再参照图1F，本发明一实施例的显示装置100包括一基板110、多个第一发光元件132以及至少一个第二发光元件134。在此说明，第二发光元件134就是在前述的制造方法中被新的第一发光元件132覆盖的原有的第一发光元件132。第一发光元件132排列于基板110上。每一个第一发光元件132背向基板110的表面上具有多个第一电极132A(仅示出于图1F)。第二发光元件134配置于基板110上。第二发光元件134背向基板110的表面S14上具有多个第二电极134A(仅示出于图1F)。第二发光元件134在基板110上的正投影P12与第一发光元件132在基板110上的正投影P14部分重叠。
本实施例的显示装置100中，第一发光元件132的第一电极132A与第二发光元件134的第二电极134A都位于背向基板110的表面上，且第二发光元件134与第一发光元件132部分重叠。换言之，第二发光元件134并不会在最终产品中发挥显示的功能。本实施例的显示装置100具有工艺成本较低的优势。
本发明的另一实施例的显示装置同样可参照图1F做说明。本实施例的显示装置100包括一基板110、多个第一发光元件132以及至少一个第二发光元件134。在此说明，第二发光元件134就是在前述的制造方法中被新的第一发光元件132覆盖的原有的第一发光元件132。第一发光元件132排列于基板110上。第二发光元件134配置于基板110上。第二发光元件134电性独立。换言之，第二发光元件134并未与任何其他元件有电性连接，也就是呈现浮置的状态。第二发光元件134在基板110上的正投影P12与第一发光元件132在基板110上的正投影P14部分重叠。
本实施例的显示装置100中，第二发光元件134电性独立，且第二发光元件134与第一发光元件132部分重叠。换言之，第二发光元件134并不会在最终产品中发挥显示的功能。本实施例的显示装置100具有工艺成本较低的优势。
在上述的实施例中，第二发光元件134位于第一发光元件132与基板110之间。此外，第一发光元件132与第二发光元件134例如是通过第一粘着层固定于基板110上，且第一粘着层110的厚度T12大于一个第一发光元件132的厚度T14与一个第二发光元件134的厚度T16的总和。具有厚度T12的第一粘着层110可避免在进行第二转移时发生第一发光元件132、第二发光元件134与基板110三者间的碰撞，进而避免因此损毁。
图2A至图2C是依照本发明的另一实施例的显示装置的制造方法的部分流程的剖面示意图。本实施例的显示装置的制造方法与图1A至图1F的实施例大致相同，在此仅说明两者的差异处。请参照图2A，本实施例的显示装置的制造方法可包括图1A至图1C的步骤，接着如图2A所示，在第一粘着层122上形成一第二粘着层124。第二粘着层124至少覆盖第一发光元件132中的至少一个姿态不良者。举例来说，可仅有第一发光元件132中姿态良好者不会被第二粘着层124覆盖。接着请参照图2B，在第二转移时将移转头50涵盖的区域内被第二粘着层124覆盖的原有的第一发光元件132以新的第一发光元件132覆盖。图2B中可见，移转头50上即使未对应第二粘着层124的位置也有新的第一发光元件132，因此移转头50在进行第二转移前拾取第一发光元件132可全面拾取，而不需刻意避开未对应第二粘着层124的位置，可加速工艺速度。同时，未对应第二粘着层124的位置的新的第一发光元件132也不会移转至第二粘着层124上。
接着请参照图2C，原有的第一发光元件132通过第一粘着层122固定于基板110上，新的第一发光元件132通过第一粘着层122与第二粘着层124固定于基板110上。第二发光元件134位于第一粘着层122与第二粘着层124之间。第二发光元件134就是在前述的制造方法中被新的第一发光元件132覆盖的原有的第一发光元件132。此实施例中，因为先形成了第二粘着层124，可进一步降低新的第一发光元件132与第二发光元件134接触时可能产生的损坏。
在完成如图1F或图2C的架构后，可继续进行接线的流程。图3A至图3I是依照本发明的一实施例的显示装置的制造方法的接线流程的剖面示意图。请参照图3A，在此以仅具有第一粘着层122的架构为例，但也可应用于具有第二粘着层124的实施例中。首先，覆盖一光刻胶层62，如图3B。接着如图3C，对光刻胶层62进行光刻蚀刻工艺以形成开口O12，开口O12位置对应于基板110上的接垫142。接着如图3D，利用光刻胶层62为掩模，对第一粘着层122进行光刻蚀刻工艺以形成开口O14，开口O12与开口O14共同使接垫142露出。接着如图3E，移除光刻胶层62。
然后，如图3F，覆盖一光刻胶层64。接着如图3G，对光刻胶层64进行光刻蚀刻工艺以形成开口O16，开口O16使第一发光元件132的一个第一电极132A、开口O14以及接垫142露出。接着如图3H，在开口O16与开口O14内填入导电材料以形成接线150。接线150的两端分别接触第一电极132A以及接垫142而使两者导通。接线150的材料可以是金属、氧化金属或其他导电材料。
图4A与图4B是依照本发明的两种实施例的显示装置的局部剖面示意图。请参照图4A，本实施例的显示装置102与图1F的显示装置100大致相同，在此仅说明两者的差异处。本实施例的显示装置102还包括多个岛状接垫144，而在图4A中仅示出一个。第一粘着层122具有多个开口O14，而在图4A中仅示出一个。每个岛状接垫144位于对应的一个开口O14内。每个岛状接垫144电性连接对应的第一发光元件132的一个第一电极132A。每个岛状接垫144的高度H12小于等于第一粘着层122的厚度T12的一半。通过岛状接垫144的设置，在进行接线工艺时所需进行的挖孔深度可以减少，进而缩短工艺时间，可降低第一发光元件132在挖孔过程中可能产生偏移或姿态倾斜的几率。
请参照图4B，本实施例的显示装置104与图2C的显示装置大致相同，在此仅说明两者的差异处。本实施例的显示装置104还包括多个岛状接垫144，而在图4B中仅示出一个。第一粘着层122具有多个第一开口O14，而在图4B中仅示出一个。第二粘着层124具有多个第二开口O18，而在图4B中仅示出一个。每个第一开口O14与对应的一个第二开口O18重叠。每个岛状接垫144位于对应的一个第一开口O14与对应的一个第二开口O18内。每个岛状接垫144电性连接对应的第一发光元件132的一个第一电极132A。每个岛状接垫144的高度H12小于等于第一粘着层122的厚度T12与一个第一发光元件132的厚度T14的总和。即使本实施例同时具有第一粘着层122与第二粘着层124，通过岛状接垫144的设置，在进行接线工艺时所需进行的挖孔深度仍可以减少，进而缩短工艺时间，可降低第一发光元件132在挖孔过程中可能产生偏移或姿态倾斜的几率。
图5是依照本发明的一实施例的显示装置的数种接垫的示意图。请参照图5，除了与图4A及图4B相同的矩形的岛状接垫144的主体的剖面形状外，还可以是三角形的岛状接垫144A的主体的剖面形状，中间挖孔的岛状接垫144B的主体的剖面形状，上半部呈圆弧状的岛状接垫144C的主体的剖面形状，亦或是其他剖面形状。此外，岛状接垫144A的主体可以全由同一材料形成，或者岛状接垫144D的主体也可以是由导电材料包覆非导电材料而成。
图6是依照本发明的一实施例的显示装置的俯视图。在此以图6说明本实施例的显示装置106的布局方式，前述各实施例的技术手段皆可应用于本实施例的显示装置106。请参照图6，显示装置106包括了阵列排列的多个第一发光元件132，这些第一发光元件132例如分别用于发出红光、绿光、蓝光或其他色光。一条接线150上可包括多个接垫142，每个接垫142连接到对应的一个第一发光元件132的一个第一电极132A。以此方式，可通过多条接线150将所有第一发光元件132都连接到驱动单元(未示出)。
综上所述，在本发明的显示装置及显示装置的制造方法中，是直接以新的发光元件将姿态不良的发光元件覆盖而不将其移除。因此，可缩短工艺时间而降低制造成本。此外，显示装置的制造方法中不需更换移转头，也可进一步加快制造速度。

Claims (13)

1.一种显示装置，包括：
一基板；
多个第一发光元件，排列于该基板上，其中每一该些第一发光元件背向该基板的表面上具有多个第一电极；以及
至少一个第二发光元件，配置于该基板上，其中该第二发光元件背向该基板的表面上具有多个第二电极，该第二发光元件在该基板上的正投影与该些第一发光元件在该基板上的正投影部分重叠，
还包括一粘着层，该些第一发光元件与该第二发光元件通过该粘着层固定于该基板上，且该粘着层的厚度大于一个该些第一发光元件的厚度与该第二发光元件的厚度的总和。
2.如权利要求1所述的显示装置，其中该第二发光元件位于该些第一发光元件与该基板之间。
3.如权利要求1所述的显示装置，还包括多个岛状接垫，其中该粘着层具有多个开口，各该岛状接垫位于对应的一个该些开口内，各该岛状接垫电性连接对应的一个该些第一电极，各该岛状接垫的高度小于等于该粘着层的厚度的一半。
4.一种显示装置，包括：
一基板；
多个第一发光元件，排列于该基板上，其中每一该些第一发光元件背向该基板的表面上具有多个第一电极；以及
至少一个第二发光元件，配置于该基板上，其中该第二发光元件背向该基板的表面上具有多个第二电极，该第二发光元件在该基板上的正投影与该些第一发光元件在该基板上的正投影部分重叠，
还包括一第一粘着层与一第二粘着层，该第一粘着层位于该基板与该第二粘着层之间，该些第一发光元件与该第二发光元件通过该第一粘着层与该第二粘着层固定于该基板上，且该第二发光元件位于该第一粘着层与该第二粘着层之间。
5.如权利要求4所述的显示装置，还包括多个岛状接垫，其中该第一粘着层具有多个第一开口，该第二粘着层具有多个第二开口，各该第一开口与对应的一个该些第二开口重叠，各该岛状接垫位于对应的一个该些第一开口与对应的一个该些第二开口内，各该岛状接垫电性连接对应的一个该些第一电极，各该岛状接垫的高度小于等于该第一粘着层的厚度与一个该些第一发光元件的厚度的总和。
6.一种显示装置，包括：
一基板；
多个第一发光元件，排列于该基板上；以及
至少一个第二发光元件，配置于该基板上，其中该第二发光元件电性独立，该第二发光元件在该基板上的正投影与该些第一发光元件在该基板上的正投影部分重叠，
还包括一粘着层，该些第一发光元件与该第二发光元件通过该粘着层固定于该基板上，且该粘着层的厚度大于一个该些第一发光元件的厚度与该第二发光元件的厚度的总和。
7.如权利要求6所述的显示装置，其中该第二发光元件位于该些第一发光元件与该基板之间。
8.如权利要求6所述的显示装置，还包括多个岛状接垫，其中该粘着层具有多个开口，各该岛状接垫位于对应的一个该些开口内，各该岛状接垫电性连接对应的一个第一电极，各该岛状接垫的高度小于等于该粘着层的厚度的一半。
9.一种显示装置，包括：
一基板；
多个第一发光元件，排列于该基板上；以及
至少一个第二发光元件，配置于该基板上，其中该第二发光元件电性独立，该第二发光元件在该基板上的正投影与该些第一发光元件在该基板上的正投影部分重叠，
还包括一第一粘着层与一第二粘着层，该第一粘着层位于该基板与该第二粘着层之间，该些第一发光元件与该第二发光元件通过该第一粘着层与该第二粘着层固定于该基板上，且该第二发光元件位于该第一粘着层与该第二粘着层之间。
10.如权利要求9所述的显示装置，还包括多个岛状接垫，其中该第一粘着层具有多个第一开口，该第二粘着层具有多个第二开口，各该第一开口与对应的一个该些第二开口重叠，各该岛状接垫位于对应的一个该些第一开口与对应的一个该些第二开口内，各该岛状接垫电性连接对应的一个第一电极，各该岛状接垫的高度小于等于该第一粘着层的厚度与一个该些第一发光元件的厚度的总和。
11.一种显示装置的制造方法，包括：
使用一转移头进行多次第一转移，以排列多个第一发光元件于一基板上，其中每次第一转移转移多个该些第一发光元件；
进行检查并标记该些第一发光元件中的至少一个姿态不良者的位置；以及
使用该转移头对该些第一发光元件中的至少一个姿态不良者的位置进行一次第二转移，以将该转移头在该第二转移时涵盖的区域内原有的该些第一发光元件中的至少一个姿态不良者以新的该些第一发光元件覆盖。
12.如权利要求11所述的显示装置的制造方法，其中进行该些第一转移前，还包括形成一第一粘着层于该基板上，该些第一转移转移该些第一发光元件于该第一粘着层上。
13.如权利要求12所述的显示装置的制造方法，其中在进行检查之后与覆盖原有的该些第一发光元件之前，还包括在该第一粘着层上形成一第二粘着层，该第二粘着层至少覆盖该些第一发光元件中的至少一个姿态不良者。
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