TWI717978B - 顯示裝置及顯示裝置的製造方法 - Google Patents

顯示裝置及顯示裝置的製造方法 Download PDF

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TWI717978B
TWI717978B TW109101856A TW109101856A TWI717978B TW I717978 B TWI717978 B TW I717978B TW 109101856 A TW109101856 A TW 109101856A TW 109101856 A TW109101856 A TW 109101856A TW I717978 B TWI717978 B TW I717978B
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light
adhesive layer
substrate
emitting element
display device
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TW109101856A
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TW202129945A (zh
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藍伊奮
吳宗典
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友達光電股份有限公司
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Priority to TW109101856A priority Critical patent/TWI717978B/zh
Priority to CN202010511417.XA priority patent/CN111668205B/zh
Priority to US16/990,983 priority patent/US11393800B2/en
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Publication of TWI717978B publication Critical patent/TWI717978B/zh
Publication of TW202129945A publication Critical patent/TW202129945A/zh

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Abstract

一種顯示裝置及顯示裝置的製造方法。顯示裝置包括一基板、多個第一發光元件以及至少一個第二發光元件。第一發光元件排列於基板上。每一個第一發光元件背向基板的表面上具有多個第一電極。第二發光元件配置於基板上。第二發光元件背向基板的表面上具有多個第二電極。第二發光元件在基板上的正投影與第一發光元件在基板上的正投影部分重疊。

Description

顯示裝置及顯示裝置的製造方法
本發明是有關於一種裝置及裝置的製造方法，且特別是有關於一種顯示裝置及顯示裝置的製造方法。
發光元件陣列顯示裝置是由設置於基板上的陣列排列的多個發光元件構成。繼承目前的發光元件的特性，發光元件陣列顯示裝置具有省電、高效率、高亮度及反應時間快等優點。但是，在製造顯示裝置時，批次轉移發光元件至基板時常發生錯位、傾斜或甚至遺漏發光元件的問題。過去的作法，需更換轉移頭來一一地移除有問題的發光元件並重新轉移，但會耗費大量的製程時間。
本發明提供一種顯示裝置及顯示裝置的製造方法，可改善製程成本過高的問題。
本發明的顯示裝置包括一基板、多個第一發光元件以及至少一個第二發光元件。第一發光元件排列於基板上。每一個第一發光元件背向基板的表面上具有多個第一電極。第二發光元件配置於基板上。第二發光元件背向基板的表面上具有多個第二電極。第二發光元件在基板上的正投影與第一發光元件在基板上的正投影部分重疊。
本發明的另一顯示裝置包括一基板、多個第一發光元件以及至少一個第二發光元件。第一發光元件排列於基板上。第二發光元件配置於基板上。第二發光元件電性獨立。第二發光元件在基板上的正投影與第一發光元件在基板上的正投影部分重疊。
在本發明的一實施例中，第二發光元件位於第一發光元件與基板之間。
在本發明的一實施例中，顯示裝置更包括一黏著層。第一發光元件與第二發光元件藉由黏著層固定於基板上，且黏著層的厚度大於一個第一發光元件的厚度與第二發光元件的厚度的總和。
在本發明的一實施例中，顯示裝置更包括多個島狀接墊。黏著層具有多個開口。各島狀接墊位於對應的一個開口內。各島狀接墊電性連接對應的一個第一電極。各島狀接墊的高度小於等於黏著層的厚度的一半。
在本發明的一實施例中，顯示裝置更包括一第一黏著層與一第二黏著層。第一黏著層位於基板與第二黏著層之間。第一發光元件與第二發光元件藉由第一黏著層與第二黏著層固定於基板上，且第二發光元件位於第一黏著層與第二黏著層之間。
在本發明的一實施例中，顯示裝置更包括多個島狀接墊。第一黏著層具有多個第一開口。第二黏著層具有多個第二開口。各第一開口與對應的一個第二開口重疊。各島狀接墊位於對應的一個第一開口與對應的一個第二開口內。各島狀接墊電性連接對應的一個第一電極。各島狀接墊的高度小於等於第一黏著層的厚度與一個第一發光元件的厚度的總和。
本發明的顯示裝置的製造方法包括下列步驟。使用一轉移頭進行多次第一轉移，以排列多個第一發光元件於一基板上。每次第一轉移轉移多個第一發光元件。進行檢查並標記第一發光元件中的至少一個姿態不良者的位置。使用轉移頭對第一發光元件中的至少一個姿態不良者的位置進行一次第二轉移，以將移轉頭在第二轉移時涵蓋的區域內原有的第一發光元件中的至少一個姿態不良者以新的第一發光元件覆蓋。
在本發明的一實施例中，進行第一轉移前，更包括形成一第一黏著層於基板上，第一轉移轉移第一發光元件於第一黏著層上。
在本發明的一實施例中，在進行檢查之後與覆蓋原有的第一發光元件之前，更包括在第一黏著層上形成一第二黏著層，第二黏著層至少覆蓋第一發光元件中的至少一個姿態不良者。
基於上述，在本發明的顯示裝置及顯示裝置的製造方法中，不移除姿態不良的發光元件，而直接以新的發光元件將其覆蓋，可縮短製程時間而降低製造成本。
圖1A至圖1F是依照本發明的一實施例的顯示裝置的製造方法的流程的剖面示意圖。本實施例的顯示裝置的製造方法包括下列步驟。請參照圖1A，首先提供一基板110。選擇性地，基板110上可先形成有一第一黏著層122。
接著請參照圖1B，使用一轉移頭50進行多次第一轉移，以排列多個第一發光元件132於基板110上。當存在第一黏著層122時，第一轉移轉移第一發光元件132於第一黏著層122上，而第一黏著層122可提供適當的定位效果。每次第一轉移轉移多個第一發光元件132。在圖1B中，僅示意地顯示轉移頭50進行一次第一轉移可涵蓋的範圍，而轉移頭50需要進行多次第一轉移才能在整個基板上排列完第一發光元件132。舉例來說，基板110上若需要排列8百萬個第一發光元件132，而轉移頭50進行一次第一轉移可轉移4萬個第一發光元件132，則需進行2百次第一轉移才能在整個基板上排列完第一發光元件132。
接著請參照圖1C，進行檢查並標記第一發光元件132中的至少一個姿態不良者的位置。圖1C中以虛線框表示第一發光元件132的正常位置。在圖1C中，舉例了一個第一發光元件132的位置產生了偏移，一個第一發光元件132的姿態傾斜，還有一個第一發光元件132並未成功從轉移頭50轉移至基板110上。
接著使用轉移頭50對第一發光元件132中的至少一個姿態不良者的位置進行一次第二轉移。圖1D中顯示轉移頭50上帶有新的第一發光元件132，並且對準欲轉移的位置。接著請參照圖1E，在第二轉移時將移轉頭50涵蓋的區域內原有的第一發光元件132中的至少一個姿態不良者以新的第一發光元件132覆蓋。本實施例中，是將移轉頭50涵蓋的區域內所有原有的第一發光元件132都以新的第一發光元件132覆蓋。最後，請參照圖1F，將轉移頭50移開，就完成了顯示裝置100的製造。
從上述可知，在本實施例的顯示裝置的製造方法中，不論是第一轉移或是第二轉移，都是使用相同的轉移頭50，可節省更換轉移頭所需的製程時間與成本。此外，在第二轉移時，是一次將轉移頭50涵蓋的區域內有問題的位置都覆蓋新的第一發光元件132，而不是一顆一顆地轉移，可縮短製程時間。
在上述實施例中，進行第二轉移時，是將移轉頭50涵蓋的區域內全部原有的第一發光元件132都以新的第一發光元件132覆蓋，如此可節省進行第二轉移前選擇性地拾取新的第一發光元件132所需的時間。但是，在其他實施例中，也可僅在有問題的位置覆蓋新的第一發光元件132以節省材料成本，但仍在一次第二轉移中將移轉頭50涵蓋的區域內有問題的位置都覆蓋新的第一發光元件132。另外，第二轉移需要進行的次數可在進行檢查並標記第一發光元件132中的至少一個姿態不良者的位置之後決定，例如是計算如何以最少次數的第二轉移涵蓋全部被標記的位置。在進行檢查並標記前，並不會對第一發光元件132進行接線，因此並不是以點亮測試的方法來確認每個第一發光元件132是否為良品。取而代之的，是由檢查設備以光學手段判斷第一發光元件132的姿態是否良好。因此，第二轉移時被覆蓋的第一發光元件132並不會接線，而是呈現電性獨立的狀態，也就是呈現浮置(floating)的狀態。
請再參照圖1F，本發明一實施例的顯示裝置100包括一基板110、多個第一發光元件132以及至少一個第二發光元件134。在此說明，第二發光元件134就是在前述的製造方法中被新的第一發光元件132覆蓋的原有的第一發光元件132。第一發光元件132排列於基板110上。每一個第一發光元件132背向基板110的表面上具有多個第一電極132A（僅繪示於圖1F）。第二發光元件134配置於基板110上。第二發光元件134背向基板110的表面S14上具有多個第二電極134A（僅繪示於圖1F）。第二發光元件134在基板110上的正投影P12與第一發光元件132在基板110上的正投影P14部分重疊。
本實施例的顯示裝置100中，第一發光元件132的第一電極132A與第二發光元件134的第二電極134A都位於背向基板110的表面上，且第二發光元件134與第一發光元件132部分重疊。換言之，第二發光元件134並不會在最終產品中發揮顯示的功能。本實施例的顯示裝置100具有製程成本較低的優勢。
本發明的另一實施例的顯示裝置同樣可參照圖1F做說明。本實施例的顯示裝置100包括一基板110、多個第一發光元件132以及至少一個第二發光元件134。在此說明，第二發光元件134就是在前述的製造方法中被新的第一發光元件132覆蓋的原有的第一發光元件132。第一發光元件132排列於基板110上。第二發光元件134配置於基板110上。第二發光元件134電性獨立。換言之，第二發光元件134並未與任何其他元件有電性連接，也就是呈現浮置的狀態。第二發光元件134在基板110上的正投影P12與第一發光元件132在基板110上的正投影P14部分重疊。
本實施例的顯示裝置100中，第二發光元件134電性獨立，且第二發光元件134與第一發光元件132部分重疊。換言之，第二發光元件134並不會在最終產品中發揮顯示的功能。本實施例的顯示裝置100具有製程成本較低的優勢。
在上述的實施例中，第二發光元件134位於第一發光元件132與基板110之間。此外，第一發光元件132與第二發光元件134例如是藉由第一黏著層固定於基板110上，且第一黏著層110的厚度T12大於一個第一發光元件132的厚度T14與一個第二發光元件134的厚度T16的總和。具有厚度T12的第一黏著層110可避免在進行第二轉移時發生第一發光元件132、第二發光元件134與基板110三者間的碰撞，進而避免因此損毀。
圖2A至圖2C是依照本發明的另一實施例的顯示裝置的製造方法的部分流程的剖面示意圖。本實施例的顯示裝置的製造方法與圖1A至圖1F的實施例大致相同，在此僅說明兩者的差異處。請參照圖2A，本實施例的顯示裝置的製造方法可包括圖1A至圖1C的步驟，接著如圖2A所示，在第一黏著層122上形成一第二黏著層124。第二黏著層124至少覆蓋第一發光元件132中的至少一個姿態不良者。舉例來說，可僅有第一發光元件132中姿態良好者不會被第二黏著層124覆蓋。接著請參照圖2B，在第二轉移時將移轉頭50涵蓋的區域內被第二黏著層124覆蓋的原有的第一發光元件132以新的第一發光元件132覆蓋。圖2B中可見，移轉頭50上即使未對應第二黏著層124的位置也有新的第一發光元件132，因此移轉頭50在進行第二轉移前拾取第一發光元件132可全面拾取，而不需刻意避開未對應第二黏著層124的位置，可加速製程速度。同時，未對應第二黏著層124的位置的新的第一發光元件132也不會移轉至第二黏著層124上。
接著請參照圖2C，原有的第一發光元件132藉由第一黏著層122固定於基板110上，新的第一發光元件132藉由第一黏著層122與第二黏著層124固定於基板110上。第二發光元件134位於第一黏著層122與第二黏著層124之間。第二發光元件134就是在前述的製造方法中被新的第一發光元件132覆蓋的原有的第一發光元件132。此實施例中，因為先形成了第二黏著層124，可進一步降低新的第一發光元件132與第二發光元件134接觸時可能產生的損壞。
在完成如圖1F或圖2C的架構後，可繼續進行接線的流程。圖3A至圖3I是依照本發明的一實施例的顯示裝置的製造方法的接線流程的剖面示意圖。請參照圖3A，在此以僅具有第一黏著層122的架構為例，但也可應用於具有第二黏著層124的實施例中。首先，覆蓋一光阻層62，如圖3B。接著如圖3C，對光阻層62進行微影蝕刻製程以形成開口O12，開口O12位置對應於基板110上的接墊142。接著如圖3D，利用光阻層62為罩幕，對第一黏著層122進行微影蝕刻製程以形成開口O14，開口O12與開口O14共同使接墊142露出。接著如圖3E，移除光阻層62。
然後，如圖3F，覆蓋一光阻層64。接著如圖3G，對光阻層64進行微影蝕刻製程以形成開口O16，開口O16使第一發光元件132的一個第一電極132A、開口O14以及接墊142露出。接著如圖3H，在開口O16與開口O14內填入導電材料以形成接線150。接線150的兩端分別接觸第一電極132A以及接墊142而使兩者導通。接線150的材料可以是金屬、氧化金屬或其他導電材料。
圖4A與圖4B是依照本發明的兩種實施例的顯示裝置的局部剖面示意圖。請參照圖4A，本實施例的顯示裝置102與圖1F的顯示裝置100大致相同，在此僅說明兩者的差異處。本實施例的顯示裝置102更包括多個島狀接墊144，而在圖4A中僅繪示一個。第一黏著層122具有多個開口O14，而在圖4A中僅繪示一個。每個島狀接墊144位於對應的一個開口O14內。每個島狀接墊144電性連接對應的第一發光元件132的一個第一電極132A。每個島狀接墊144的高度H12小於等於第一黏著層122的厚度T12的一半。藉由島狀接墊144的設置，在進行接線製程時所需進行的挖孔深度可以減少，進而縮短製程時間，可降低第一發光元件132在挖孔過程中可能產生偏移或姿態傾斜的機率。
請參照圖4B，本實施例的顯示裝置104與圖2C的顯示裝置大致相同，在此僅說明兩者的差異處。本實施例的顯示裝置104更包括多個島狀接墊144，而在圖4B中僅繪示一個。第一黏著層122具有多個第一開口O14，而在圖4B中僅繪示一個。第二黏著層124具有多個第二開口O18，而在圖4B中僅繪示一個。每個第一開口O14與對應的一個第二開口O18重疊。每個島狀接墊144位於對應的一個第一開口O14與對應的一個第二開口O18內。每個島狀接墊144電性連接對應的第一發光元件132的一個第一電極132A。每個島狀接墊144的高度H12小於等於第一黏著層122的厚度T12與一個第一發光元件132的厚度T14的總和。即使本實施例同時具有第一黏著層122與第二黏著層124，藉由島狀接墊144的設置，在進行接線製程時所需進行的挖孔深度仍可以減少，進而縮短製程時間，可降低第一發光元件132在挖孔過程中可能產生偏移或姿態傾斜的機率。
圖5是依照本發明的一實施例的顯示裝置的數種接墊的示意圖。請參照圖5，除了與圖4A及圖4B相同的矩形的島狀接墊144的主體的剖面形狀外，還可以是三角形的島狀接墊144A的主體的剖面形狀，中間挖孔的島狀接墊144B的主體的剖面形狀，上半部呈圓弧狀的島狀接墊144C的主體的剖面形狀，亦或是其他剖面形狀。此外，島狀接墊144A的主體可以全由同一材料形成，或者島狀接墊144D的主體也可以是由導電材料包覆非導電材料而成。
圖6是依照本發明的一實施例的顯示裝置的上視示意圖。在此以圖6說明本實施例的顯示裝置106的佈局方式，前述各實施例的技術手段皆可應用於本實施例的顯示裝置106。請參照圖6，顯示裝置106包括了陣列排列的多個第一發光元件132，這些第一發光元件132例如分別用於發出紅光、綠光、藍光或其他色光。一條接線150上可包括多個接墊142，每個接墊142連接到對應的一個第一發光元件132的一個第一電極132A。以此方式，可藉由多條接線150將所有第一發光元件132都連接到驅動單元（未繪示）。
綜上所述，在本發明的顯示裝置及顯示裝置的製造方法中，是直接以新的發光元件將姿態不良的發光元件覆蓋而不將其移除。因此，可縮短製程時間而降低製造成本。此外，顯示裝置的製造方法中不需更換移轉頭，也可進一步加快製造速度。
50:轉移頭 100, 102, 104, 106:顯示裝置 110:基板 122:第一黏著層 124:第二黏著層 132:第一發光元件 132A:第一電極 134:第二發光元件 134A:第二電極 S12, S14:表面 P12, P14:正投影 T12, T14, T16:厚度 62, 64:光阻層 O12, O14, O16, O18:開口 142:接墊 150:接線 144:島狀接墊 H12:高度
圖1A至圖1F是依照本發明的一實施例的顯示裝置的製造方法的流程的剖面示意圖。 圖2A至圖2C是依照本發明的另一實施例的顯示裝置的製造方法的部分流程的剖面示意圖。 圖3A至圖3I是依照本發明的一實施例的顯示裝置的製造方法的接線流程的剖面示意圖。 圖4A與圖4B是依照本發明的兩種實施例的顯示裝置的局部剖面示意圖。 圖5是依照本發明的一實施例的顯示裝置的數種接墊的示意圖。 圖6是依照本發明的一實施例的顯示裝置的上視示意圖。
100:顯示裝置
110:基板
122:第一黏著層
132:第一發光元件
132A:第一電極
134:第二發光元件
134A:第二電極
S12,S14:表面
P12,P14:正投影
T12,T14,T16:厚度

Claims (14)

  1. 一種顯示裝置，包括：一基板；多個第一發光元件，排列於該基板上，其中每一該些第一發光元件背向該基板的表面上具有多個第一電極；至少一個第二發光元件，配置於該基板上，其中該第二發光元件背向該基板的表面上具有多個第二電極，該第二發光元件在該基板上的正投影與該些第一發光元件在該基板上的正投影部分重疊，且該第二發光元件位於該些第一發光元件與該基板之間；一黏著層，其中該些第一發光元件與該第二發光元件藉由該黏著層固定於該基板上，且該黏著層具有多個開口；以及多個接墊，各該接墊位於對應的一個該些開口內，且各該接墊電性連接對應的一個該些第一電極。
  2. 如請求項1所述的顯示裝置，其中該黏著層的厚度大於一個該些第一發光元件的厚度與該第二發光元件的厚度的總和。
  3. 如請求項1所述的顯示裝置，其中該些接墊包括多個島狀接墊，各該島狀接墊的高度小於等於該黏著層的厚度的一半。
  4. 如請求項1所述的顯示裝置，其中該黏著層更包括一第一黏著層與一第二黏著層，該第一黏著層位於該基板與該第二黏著層之間，該些第一發光元件與該第二發光元件藉由該第一黏 著層與該第二黏著層固定於該基板上，且該第二發光元件位於該第一黏著層與該第二黏著層之間。
  5. 如請求項4所述的顯示裝置，其中該些接墊包括多個島狀接墊，該第一黏著層具有多個第一開口，該第二黏著層具有多個第二開口，各該第一開口與對應的一個該些第二開口重疊，各該島狀接墊位於對應的一個該些第一開口與對應的一個該些第二開口內，各該島狀接墊的高度小於等於該第一黏著層的厚度與一個該些第一發光元件的厚度的總和。
  6. 一種顯示裝置，包括：一基板；多個第一發光元件，排列於該基板上；以及至少一個第二發光元件，配置於該基板上，其中該第二發光元件電性獨立，該第二發光元件在該基板上的正投影與該些第一發光元件在該基板上的正投影部分重疊。
  7. 如請求項6所述的顯示裝置，其中該第二發光元件位於該些第一發光元件與該基板之間。
  8. 如請求項6所述的顯示裝置，更包括一黏著層，該些第一發光元件與該第二發光元件藉由該黏著層固定於該基板上，且該黏著層的厚度大於一個該些第一發光元件的厚度與該第二發光元件的厚度的總和。
  9. 如請求項8所述的顯示裝置，更包括多個島狀接墊，其中該黏著層具有多個開口，各該島狀接墊位於對應的一個該些 開口內，各該島狀接墊電性連接對應的一個該些第一電極，各該島狀接墊的高度小於等於該黏著層的厚度的一半。
  10. 如請求項6所述的顯示裝置，更包括一第一黏著層與一第二黏著層，該第一黏著層位於該基板與該第二黏著層之間，該些第一發光元件與該第二發光元件藉由該第一黏著層與該第二黏著層固定於該基板上，且該第二發光元件位於該第一黏著層與該第二黏著層之間。
  11. 如請求項10所述的顯示裝置，更包括多個島狀接墊，其中該第一黏著層具有多個第一開口，該第二黏著層具有多個第二開口，各該第一開口與對應的一個該些第二開口重疊，各該島狀接墊位於對應的一個該些第一開口與對應的一個該些第二開口內，各該島狀接墊電性連接對應的一個該些第一電極，各該島狀接墊的高度小於等於該第一黏著層的厚度與一個該些第一發光元件的厚度的總和。
  12. 一種顯示裝置的製造方法，包括：使用一轉移頭進行多次第一轉移，以排列多個第一發光元件於一基板上，其中每次第一轉移轉移多個該些第一發光元件；進行檢查並標記該些第一發光元件中的至少一個姿態不良者的位置；以及使用該轉移頭對該些第一發光元件中的至少一個姿態不良者的位置進行一次第二轉移，以將該移轉頭在該第二轉移時涵蓋的區域內原有的該些第一發光元件中的至少一個姿態不良者以新的 該些第一發光元件覆蓋。
  13. 如請求項12所述的顯示裝置的製造方法，其中進行該些第一轉移前，更包括形成一第一黏著層於該基板上，該些第一轉移轉移該些第一發光元件於該第一黏著層上。
  14. 如請求項13所述的顯示裝置的製造方法，其中在進行檢查之後與覆蓋原有的該些第一發光元件之前，更包括在該第一黏著層上形成一第二黏著層，該第二黏著層至少覆蓋該些第一發光元件中的至少一個姿態不良者。
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