A light-emitting device is provided. The light-emitting device includes a light-emitting element. The light-emitting device also includes a wavelength conversion element disposed on the light-emitting element. The wavelength conversion element has a first refractive index in a first wavelength. The light-emitting device further includes a light blocking element surrounding the wavelength conversion element. The light blocking element has a second refractive index in the first wavelength. The second refractive index is greater than the first refractive index.

BACKGROUND

Field of the Disclosure

The embodiments of the disclosure relate to a light-emitting device, and in particular to a light-emitting device with light-emitting diodes.

Description of the Related Art

As digital technology develops, light-emitting devices are becoming more widely used in our society. For example, light-emitting devices have been applied in modern information and communication devices such as televisions, notebooks, computers, mobile phones and smartphones. In addition, each generation of light-emitting devices has been developed to be thinner, lighter, smaller, and more fashionable. These light-emitting devices include light-emitting diode light-emitting devices.

The recombination of electron and hole in the light-emitting diode may produce electromagnetic radiation (such as light) through the current at the p-n junction. For example, in the forward bias p-n junction formed by direct band gap materials such as GaAs or GaN, the recombination of electron and hole injected into the depletion region results in electromagnetic radiation. The aforementioned electromagnetic radiation may lie in the visible region or the non-visible region. Materials with different band gaps may be used to form light-emitting diodes of different colors.

Since mass production has become the tendency recently in the light-emitting diode industry, any increase in the yield of manufacturing light-emitting diodes will reduce costs and result in huge economic benefits. However, existing light-emitting devices have not been satisfactory in every respect.

Therefore, a light-emitting diode which may further increase the production yield and a light-emitting device which is manufactured from the light-emitting diode are needed.

SUMMARY

A light-emitting device is provided. The light-emitting device includes a light-emitting element. The light-emitting device also includes a wavelength conversion element disposed on the light-emitting element. The wavelength conversion element has a first refractive index in a first wavelength. The light-emitting device further includes a light blocking element surrounding the wavelength conversion element. The light blocking element has a second refractive index in the first wavelength. The second refractive index is greater than the first refractive index.

DETAILED DESCRIPTION OF THE DISCLOSURE

The light-emitting device of the present disclosure is described in detail in the following description. In the following detailed description, for purposes of explanation, numerous specific details and embodiments are set forth in order to provide a thorough understanding of the present disclosure. The specific elements and configurations described in the following detailed description are set forth in order to clearly describe the present disclosure. It will be apparent, however, that the exemplary embodiments set forth herein are used merely for the purpose of illustration, and the inventive concept may be embodied in various forms without being limited to those exemplary embodiments. In addition, the drawings of different embodiments may use like and/or corresponding numerals to denote like and/or corresponding elements in order to clearly describe the present disclosure. However, the use of like and/or corresponding numerals in the drawings of different embodiments does not suggest any correlation between different embodiments. In addition, in this specification, expressions such as “first material layer disposed on/over a second material layer”, may indicate the direct contact of the first material layer and the second material layer, or it may indicate a non-contact state with one or more intermediate layers between the first material layer and the second material layer. In the above situation, the first material layer may not be in direct contact with the second material layer.

It should be noted that the elements or devices in the drawings of the present disclosure may be present in any form or configuration known to those skilled in the art. In addition, the expression “a layer overlying another layer”, “a layer is disposed above another layer”, “a layer is disposed on another layer” and “a layer is disposed over another layer” may indicate that the layer is in direct contact with the other layer, or that the layer is not in direct contact with the other layer, there being one or more intermediate layers disposed between the layer and the other layer.

In addition, in this specification, relative expressions are used. For example, “lower”, “bottom”, “higher” or “top” are used to describe the position of one element relative to another. It should be appreciated that if a device is flipped upside down, an element that is “lower” will become an element that is “higher”.

The terms “about” and “substantially” typically mean +/−20% of the stated value, more typically +/−10% of the stated value, more typically +/−5% of the stated value, more typically +/−3% of the stated value, more typically +/−2% of the stated value, more typically +/−1% of the stated value and even more typically +/−0.5% of the stated value. The stated value of the present disclosure is an approximate value. When there is no specific description, the stated value includes the meaning of “about” or “substantially”.

This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. The drawings are not drawn to scale. In addition, structures and devices are shown schematically in order to simplify the drawing.

The term “substrate” is meant to include devices formed within a transparent substrate and the layers overlying the transparent substrate. All transistor element needed may be already formed over the substrate. However, the substrate is represented with a flat surface in order to simplify the drawing. The term “substrate surface” is meant to include the uppermost exposed layers on a transparent substrate, such as an insulating layer and/or metallurgy lines.

FIGS. 1A-1Gare cross-sectional views of various stages of a process for forming a light-emitting device100A in accordance with some embodiments of the present disclosure. In some embodiments, as shown inFIG. 1, a plurality of light-emitting elements104are formed over a growth substrate102. In some embodiments, the growth substrate102is a wafer substrate which includes silicon or a sapphire substrate which includes alumina oxide. In other embodiments, the growth substrate102is a substrate including GaP, GaAs, AlGaAs or SiC.

In some embodiments, the light-emitting element104is for example a micro light-emitting diode (μLED). The size of the chip of the μLED is in a range of about 1 μm to about 100 μm. The light-emitting element104can be a mini light-emitting diode. The size of the chip of the mini LED is in a range of about 100 μm to about 300 μm. The light-emitting element104can be a light-emitting diode. The size of the chip of the LED is in a range of about 300 μm to about 10 mm. The recombination of electron and hole in the μLED may produce electromagnetic radiation (such as light) through the current at the p-n junction. For example, in the forward bias p-n junction formed by direct band gap materials such as GaAs or GaN, the recombination of electron and hole injected into the depletion region results in electromagnetic radiation. The aforementioned electromagnetic radiation may lie in the visible region or the non-visible region. Materials with different band gaps may be used to form light-emitting diodes of different colors.

In some embodiments, the light-emitting element104includes a p-type semiconductor layer, an n-type semiconductor layer and a light-emitting layer disposed between them. The p-type semiconductor layer may provide holes, and the n-type semiconductor layer may provide electrons. As a result, the holes and the electrons recombine to generate electromagnetic radiation. The semiconductor layers may include, but are not limited to, AlN, GaN, GaAs, InN, AlGaN, AlInN, InGaN, AlInGaN or a combination thereof.

The light-emitting layer may include, but is not limited to, homojunction, heterojunction, single-quantum well (SQW), multiple-quantum well (MQW) or any other applicable structure. In some embodiments, the light-emitting layer includes un-doped n type InxGa(1−x)N. In other embodiments, the light-emitting layer includes such materials as AlxInyGa(1−x−y)N and other materials. Moreover, the light-emitting layer may include a multiple-quantum well structure with multiple-quantum layers (such as InGaN) and barrier layers (such as GaN) arranged alternately. Moreover, the light-emitting layer may be formed by metalorganic chemical vapor deposition (MOCVD), molecular beam epitaxy (MBE), hydride vapor phase epitaxy (HVPE), liquid phase epitaxy (LPE) or any other applicable chemical vapor deposition process.

As shown inFIG. 1A, conductive pads106are formed on surfaces of the light-emitting elements104. The conductive pads106are configured to electrically connect the light-emitting elements104and other conductive elements. The material of the conductive pad106may include, but is not limited to, copper (Cu), aluminum (Al), molybdenum (Mo), tungsten (W), gold (Au), chromium (Cr), nickel (Ni), platinum (Pt), titanium (Ti), iridium (Ir), Rhodium (Rh), an alloy of the above, a combination of the above, or any other applicable material.

As shown inFIG. 1B, the light-emitting elements104are attached to a carrier substrate108, and the growth substrate102is removed from the light-emitting elements104in accordance with some embodiments. In some embodiments, the light-emitting elements104are attached to the carrier substrate108through the conductive pads106and an adhesive layer110. In some embodiments, the carrier substrate108is a substrate that the light-emitting elements104put on temporarily. In the subsequent processes, the light-emitting elements104are removed from the carrier substrate108. The carrier substrate108may include a glass substrate, a ceramic substrate, a plastic substrate or another applicable substrate. The material of the adhesive layer110can be a polymer or another applicable material. In some embodiments, the light-emitting elements104are transferred to the carrier substrate108from the growth substrate102by a laser lift off (LLO) process.

As shown inFIG. 1C, a supporting structure112is formed to surround the light-emitting elements104and the conductive pads106in accordance with some embodiments. The supporting structure112is configured to protect the light-emitting elements104and the conductive pads106from damage or pollution in subsequent processes. The material of the supporting structure112may comprise, but is not limited to, resin or another applicable material. In some embodiments, the supporting structure112is made of black resin. The supporting structure112may be formed by a coating process. In some embodiments, a resin material is coated to fill the space between two adjacent light-emitting elements104and cover top surfaces of the light-emitting elements104. Next, a patterning process is performed to remove a portion of the resin material to expose the top surfaces of the light-emitting elements104.

As shown inFIG. 1D, the light-emitting elements104, the conductive pads106and the supporting structure112are transferred to a transfer head114in accordance with some embodiments. The transfer head114is used to pick up the light-emitting elements104and put them on other substrate. In some embodiments, the transfer head114may be disposed on a microelectromechanical system (MEMS) device (not shown). In some embodiments, the light-emitting elements104are transferred to the transfer head114by a vacuum suction force or a static electricity force. In addition, scribe lines116are formed during the transferring process is performed. The scribe line116is formed by cutting the supporting structure112.FIG. 1Dillustrates that three light-emitting elements104constitute a group and these light-emitting elements104are between two adjacent scribe lines116. The amounts of the light-emitting elements104of the group can be adjusted, and the scope of disclosure is not intended to be limiting.

As shown inFIG. 1E, the light-emitting elements104are transferred to a substrate118from the transfer head114, in accordance with some embodiments. In order to clearly illustrate the relation between various elements,FIG. 1Eand following figures only illustrate the positional relation between one group consisted of three light-emitting elements104and other elements. In some embodiments, the substrate118may include a transparent or nontransparent substrate such as a glass substrate, a ceramic substrate, a plastic substrate or another applicable substrate. As shown inFIG. 1E, a circuit layer120is formed on the substrate118. The substrate118may be a carrier substrate. The circuit layer120may include a dielectric layer (not shown) and a plurality of conductive elements (not shown) formed therein. The dielectric layer may include, but is not limited to, silicon oxide, silicon nitride, silicon oxynitride or another applicable material. The conductive elements may include various passive and active elements, such as capacitors (e.g., metal-insulator-metal capacitor, MIMCAP), inductors, diodes, thin film transistors (TFT), metal-oxide-semiconductor field effect transistors (MOSFETs), complementary MOS (CMOS) transistors, bipolar junction transistors (BJTs), laterally diffused MOS (LDMOS) transistors, high-power MOS transistors, or another type of transistor. As shown inFIG. 1E, the light-emitting element104is electrically connected to the circuit layer120through the conductive pads106.

As shown inFIG. 1F, a structure200A is attached on top surfaces of the light-emitting elements104and the supporting structure112, in accordance with some embodiments. The detail of the process for forming the structure200A will be described later. In some embodiments, as shown inFIG. 1F, the structure200A includes a light blocking element122, a red color conversion element124, a green color conversion element126and a blue color conversion element128. The red color conversion element124, the green color conversion element126, or the blue color conversion element128is also called as a wavelength conversion element in general. That is to say, in the present disclosure, the color conversion element is the same as the wavelength conversion element. The red color conversion element124, the green color conversion element126and the blue color conversion element128are surrounded by the light blocking element122, and are separated from each other by the light blocking element122. In the present disclosure, the term “surround” can cover the “completely surround” and “partially surround” embodiments. Moreover, the red color conversion element124, the green color conversion element126and the blue color conversion element128cover a portion of the top surfaces of the light-emitting elements104. In some embodiments, the light blocking element122covers a portion of the top surfaces of the light-emitting elements104, and cover a top surface of the supporting structure112. Optionally, the scribe lines116are located under the light blocking element122. The structure200A may be attached to the light-emitting elements104by a transparent adhesive layer (not shown).

The light blocking element122can be used to shield the element or region which is not used to display colors in the light-emitting device100A. For example, the light blocking element122may be used to shield the data lines and scan lines.

As shown inFIG. 1F, the color conversion elements124,126and128are over the light-emitting elements104. In some embodiments, the red color conversion element124, the green color conversion element126and the blue color conversion element128respectively correspond to a red pixel, a green pixel and a blue pixel. The material of the red color conversion element124, the green color conversion element126and the blue color conversion element128include, but is not limited to, a quantum dot film, a fluorescent material, or another wavelength conversion material. For example, the color conversion elements124,126and128are organic or inorganic layers blended with a quantum dot. The quantum dot may include, but is not limited to, zinc, cadmium, selenium, sulfur, InP, GaSb, GaAs, CdSe, CdS, ZnS or a combination thereof. The grain diameter of the quantum dot may range from about 1 nm-30 nm, but the present disclosure is not limited thereto.

When the quantum dots with different grain diameters are excited, the spectrum of light is altered and a different wavelength of light is emitted. For example, the excitation of the quantum dots with a smaller grain diameter results in emitting a shorter wavelength of light (such as blue light), and the excitation of the quantum dots with a greater grain diameter results in emitting a longer wavelength of light (such as red light). Therefore, by fine-tuning the grain diameter of the quantum dot, different wavelengths of light can be generated, and thereby a light-emitting device with a wide color gamut is achieved. For example, the red color conversion element124blended with a quantum dot having the first grain diameter may emit light of a red color after excitation. The green color conversion element126blended with a quantum dot having the second grain diameter may emit light of a green color after excitation. The blue color conversion element128blended with a quantum dot having the third grain diameter may emit light of a blue color after excitation.

In some embodiments, the refractive index (n1) of the light blocking element122is greater than the refractive index (n2) of the color conversion elements124,126or128. In addition, in some embodiments, the difference between the refractive index (n1) and the refractive index (n2) is greater than 1. For example, the difference between the refractive index of the light blocking element122and the refractive index of the red color conversion element124is greater than 1. The intensity I1of the light emitted from the light-emitting elements104and the intensity I2of the light reflected from the light blocking element122fit the following equation:

The equation implies that the intensity I2of the light is proportional to the difference between the refractive index (n1) and the refractive index (n2). That is, the greater the difference between the refractive index (n1) and the refractive index (n2) is, the greater the intensity I2is. In some cases, when the difference between the refractive index of the light blocking element122and the refractive index of the wavelength conversion element is greater than 1, the reflective light has greater intensity. As a result, the intensity of the emitting light of the light-emitting device is improved.

In some embodiments, the refractive index of the light blocking element122is greater than 2. For example, the material of the light blocking element122includes, but is not limited to, zirconium oxide (ZrO2), potassium-sodium niobate (KNbO3), silicon carbide (SiC), gallium phosphide (GaP), gallium arsenide (GaAs), zinc oxide (ZnO), silicon (Si), germanium (Ge), or silicon-germanium (SiGe). In some embodiments, the difference between the refractive index of the light blocking element122and the refractive index of the color conversion elements124,126or128greater than 1 is measured in the wavelength of about 630 nm. Since the light blocking element122may not be able to easily absorb longer wavelengths of light such as red light, a greater difference between the refractive index of the light blocking element122and the refractive index of the color conversion elements124,126or128in the wavelength of about 630 nm can assist in improving the efficiency of color conversion for red light.

In some embodiments, the light-emitting elements104emit blue light, and the blue color conversion element128of the blue pixel may be replaced by a transparent filler. In some embodiments, the light-emitting element104emits UV light, or other visible or invisible lights. In some embodiments, the extinction coefficient of the light blocking element122is greater than the extinction coefficient of the color conversion element124,126, or128measured in the wavelength of about 450 nm. In some embodiments, the extinction coefficient of the supporting structure112is greater than the extinction coefficient of the light-emitting element104in the wavelength of about 450 nm. In some embodiments, the extinction coefficient of the light blocking structure122is greater than the extinction coefficient of the light-emitting elements104. When the extinction coefficient of the light blocking element122is greater than that of the light-emitting element104and than that of the wavelength conversion element124,126, or128in the wavelength of about 450 nm, the blue light emitted from the light-emitting elements104may be absorbed more efficiently by the light blocking element122or the supporting structure112. As a result, light leakage can be prevented or colorimetric purity of the light-emitting device is enhanced.

As shown inFIG. 1G, a light filter layer130, a protective layer132and a cover layer134are disposed on the light blocking element122, the color conversion elements124,126and128sequentially in accordance with some embodiments. As a result, a light-emitting device100A is created. The light filter layer130may allow specific wavelength of light to pass through. For example, the blue light filter layer allows wavelength of light between about 400 nm and about 500 nm to pass through, the green light filter layer allows wavelength of light between about 500 nm and about 570 nm to pass through, and the red light filter layer allows wavelength of light between about 620 nm and about 750 nm to pass through. In some embodiments, the light filter layer130is a red light filter layer disposed over the red color conversion element124, a green light filter layer disposed over the green color conversion element126, or a light filter layer capable of filtering blue light disposed over the red color conversion element124and the green color conversion element126.FIG. 1Gillustrates that the light filter layer130extends from the top surface of the red color conversion element124to the top surface of the green color conversion element126continually. Many variations and/or modifications can be made to embodiments of the disclosure. In some embodiments, the light filter layer130may cover the top surface of the red color conversion element124and cover the top surface of the green color conversion element126. In some embodiments, the light filter layer130does not cover the top surface of the blue color conversion element128. In some embodiments, the light filter layer130is a pigment filter made of organic films. In some embodiments, the light filter layer130is a multi-film stacked by silicon oxide film, silicon nitride film, titanium oxide film and other applicable films. In some embodiments, the light filter layer130covers a portion of the light blocking element122in order to prevent light leakage.

The protective layer132is configured to prevent the color conversion elements124,126and128from damage due to the environment. As shown inFIG. 1G, the protective layer132covers the top surface of the light blocking element122, the light filter layer130and the blue color conversion element128, and covers the side surface of the light blocking element122and the light filter layer130. In some embodiments, the protective layer132is in direct contact with the top surface of the blue color conversion element128. In addition, the protective layer132can provide a plane surface for disposing the cover layer134. The material of the protective layer132may include, but is not limited to, phosphosilicate glass (PSG), borophosphosilicate glass (BPSG), silicon oxide, silicon nitride, silicon oxynitride, or organic materials.

The cover layer134is used as the outer surface of the light-emitting device100A. As shown inFIG. 1G, the cover layer134covers the top surface of the protective layer132. The material of the cover layer134includes, but is not limited to, glass, quartz, poly(methyl methacrylate) (PMMA), polycarbonate (PC), polyimide (PI) or other applicable materials.

In some embodiments, the angle θ1 constituted by the top surface104T of the light-emitting elements104and the side surface122S of the light blocking element122is greater than the angle θ2 constituted by the top surface122T of the light blocking element122and the side surface130S of the light filter layer130. In some embodiments, the angle θ2 is an acute angle. When the angle θ2 is smaller than 90°, it prevents peeling when the protective layer is formed. In some cases, the angle θ2 is not greater than the angle θ1. When the angle θ2 is smaller than angle θ1, it assists in the diffusion of light, or prevents the light from mixing with light from adjacent pixels. In addition, the angle θ1 may be an angle constituted by the bottom surface and the side surface of the color conversion elements124,126and128. The angle θ2 may be an angle constituted by the side surface of the light filter layer130and the interface between the light filter layer130and the light block element122.

In some embodiments, the refractive index (n3) of the light-emitting elements104is greater than the refractive index (n2) of the color conversion element124,126, or128, the refractive index (n2) of the color conversion element124,126, or128is greater than the refractive index (n4) of the light filter layer130, and the refractive index (n4) of the light filter layer130is greater than the refractive index (n5) of the protective layer132. In some embodiments, the difference between the refractive index of two adjacent mediums is smaller than 0.5. When the difference between the refractive index of two adjacent mediums is smaller than 0.5, the refracted light may have smaller angle of refraction. As a result, the light-emitting efficiency of the light-emitting device100A is improved.

In some embodiments, the hardness of the light blocking element122is greater than that of the supporting structure112. When the hardness of the light blocking element122is greater than that of the supporting structure112, the stability is enhanced during assembly of the structure200A and the light-emitting elements104. In some embodiments, the flexibility of the light blocking element122is smaller than that of the supporting structure112. When the flexibility of the light blocking element122is smaller than that of the supporting structure112, the stability is enhanced during assembly of the structure200A and the light-emitting elements104.

FIGS. 2A-2Dare cross-sectional views of various stages of a process for forming a structure200A in accordance with some embodiments of the present disclosure. As shown inFIG. 2A, a carrier substrate136is provided and a light blocking layer138is formed on the carrier substrate136, in accordance with some embodiments. The carrier substrate136is used as a substrate for disposing subsequently formed element. The carrier substrate136may be a glass substrate, a ceramic substrate, a plastic substrate or another applicable substrate.

The light blocking layer138is a material for forming the light blocking element122. The light blocking layer138may be formed by a deposition process or a crystal growth process. The deposition process includes, but is not limited to, chemical vapor deposition (CVD), sputtering, resistive thermal evaporation, electron beam evaporation, and any other applicable methods. The chemical vapor deposition may include, but is not limited to, low pressure chemical vapor deposition (LPCVD), low temperature chemical vapor deposition (LTCVD), rapid thermal chemical vapor deposition (RTCVD), plasma enhanced chemical vapor deposition (PECVD), atomic layer deposition (ALD), and any other applicable methods.

As shown inFIG. 2B, the light blocking layer138is patterned to form the light blocking element122, in accordance with some embodiments. The light blocking layer138may be patterned by a photolithography process. The photolithography process includes, but is not limited to, photoresist coating (e.g., spin-on coating), soft baking, mask alignment, exposure, post-exposure baking, developing the photoresist, rinsing and drying (e.g., hard baking), dry etching, or wet etching. The photolithography process may also be implemented or replaced by another proper method such as maskless photolithography, electron-beam writing or ion-beam writing. After the light blocking element122is formed, a plurality of openings U surrounded by the light blocking element122are formed, and a portion of the top surface of the carrier substrate136is exposed.

As shown inFIG. 2C, the red color conversion element124, the green color conversion element126and the blue color conversion element128are formed in the openings U, in accordance with some embodiments. In some embodiments, the material of the color conversion element is sprayed into the openings U by an inkjet or a printing process. In some embodiments, the light blocking element122has the thickness T1, and the color conversion element124,126or128has the thickness T2. When the thickness T2 is smaller than the thickness T1, it prevents the material of different color conversion element from mixture. In some embodiments, the width W1 of the bottom surface of the color conversion element124,126or128is smaller than the width W2 of the top surface of the color conversion element124,126or128. When the width W1 is smaller than the width W2, the light-emitting efficiency or the angle of the vision is improved.

As shown inFIG. 2D, the carrier substrate136is removed from the light blocking element122, the red color conversion element124, the green color conversion element126and the blue color conversion element128, and the structure200A is created, in accordance with some embodiments. In some embodiments, the carrier substrate136is removed by heating, irradiation or another applicable method.

FIGS. 2A-2Dillustrate that the light blocking element122is made of a single component. Many variations and/or modifications can be made to embodiments of the disclosure. The light blocking element122may be a composite structure including two or more materials. Referring toFIGS. 3A-3D,FIGS. 3A-3Dare cross-sectional views of various stages of a process for forming a structure200B in accordance with some embodiments of the present disclosure. As shown inFIG. 3A, a patterned photoresist element139is formed on the carrier substrate136, and a capping layer140is formed conformally over the photoresist element139in accordance with some embodiments. The photoresist element139and the capping layer140may be formed by a multiple deposition or a photolithography process. In some embodiments, the light blocking element122includes the photoresist element139and the capping layer140covering the photoresist element139. The photoresist element139includes, but is not limited to, black photoresist, black printing ink, black resin or any other suitable light-shielding materials.

In some embodiments, the top and side surfaces of the photoresist element139are covered by the capping layer140. In this embodiment, the capping layer140includes silicon. More specially, the capping layer140is made of amorphous silicon or poly-silicon so that the light blocking element122has better light blocking or waterproofing ability. In some embodiments, the capping layer140includes high-k materials. The high-k materials may include, but is not limited to, metal oxide, metal nitride, metal silicide, transition metal oxide, transition metal nitride, transition metal silicide, transition metal oxynitride, metal aluminate, zirconium silicate, and zirconium aluminate. Examples of the material of the high-k material include, but are not limited to, LaO, AlO, ZrO, TiO, Ta2O5, Y2O3, SrTiO3(STO), BaTiO3(BTO), BaZrO, HfO2, HfO3, HfZrO, HfLaO, HfSiO, HfSiON, LaSiO, AlSiO, HfTaO, HfTiO, HfTaTiO, HfAlON, (Ba,Sr)TiO3(BST), Al2O3, any other applicable high-k material, and combinations thereof.

As shown inFIG. 3B, the red color conversion element124, the green color conversion element126and the blue color conversion element128are formed in the openings U, in accordance with some embodiments. In some embodiments, the materials of the color conversion elements124,126and128are sprayed into the openings U by an inkjet or a printing process.

As shown inFIG. 3C, a planar layer142is formed over the color conversion elements124,126,128and the capping layer140, in accordance with some embodiments. The outer surface of the planar layer142may be used to attach the light-emitting elements104for subsequent attaching process. In some embodiments, the planar layer142includes, but is not limited to, organic material or inorganic material such as silicon oxide, silicon nitride, silicon oxynitride, and other dielectric materials. As shown inFIG. 3C, the top and side surfaces of the color conversion elements124,126and128are covered by the planar layer142. As a result, it prevents the color conversion elements124,126and128from being damaged due to subsequent processes.

As shown inFIG. 3D, the carrier substrate136is removed from the light blocking element122, the red color conversion element124, the green color conversion element126and the blue color conversion element128, and the structure200B is created in accordance with some embodiments. In some embodiments, the carrier substrate136is removed by heating, irradiation, or another applicable method.

Referring toFIG. 4,FIG. 4is a cross-sectional view of a light-emitting device100B in accordance with some embodiments of the present disclosure. One of the differences between the light-emitting device100A shown inFIG. 1Gand the light-emitting device100B shown inFIG. 4is that the structure200A in the light-emitting device100A is replaced with the structure200B. In some embodiments, the planar layer142is disposed between the light-emitting elements104and the light blocking element122. As shown inFIG. 4, the planar layer142covers the top surfaces of the light-emitting elements104and the supporting structure112. In addition, a portion of the capping layer140is not covered by the light filter layer130. The light-emitting device100B with the structure200B may have better light blocking or waterproof ability.

Many variations and/or modifications can be made to embodiments of the disclosure. Referring toFIG. 5,FIG. 5is a cross-sectional view of a structure200C in accordance with some embodiments of the present disclosure. As shown inFIG. 5, an active element144is formed in the light blocking element122, in accordance with some embodiments. In some embodiments, the active element144includes a thin film transistor such as a switch transistor, a driver, a reset transistor, or another active element.

FIG. 5illustrates the active element144is embedded in the light blocking element122. Many variations and/or modifications can be made to embodiments of the disclosure. In some embodiments, a portion of the active element144is formed over the light blocking element122. In some embodiments, the active element144is formed over the surface of the light blocking element122. Multiple processes may be performed on the light blocking element122to form the active element144. Alternatively, the active element144may be formed on another substrate (not shown), and next be transferred to the surface of the light blocking element122.

Referring toFIGS. 6A and 6B,FIGS. 6A and 6Bare cross-sectional views of two stages of a process for forming a light-emitting device100C in accordance with some embodiments of the present disclosure. The materials and processing steps to arrive at the intermediate structure illustrated inFIG. 6Amay be similar to the previously described embodiment inFIG. 1A through 1E, and thus, the description is not repeated herein. The details of this embodiment that are similar to those of the previously described embodiment will not be repeated herein.

As shown inFIG. 6A, a wire146is formed in the supporting structure112, in accordance with some embodiments. The wire146is electrically connected to the light-emitting elements104through wires121and121′ which are formed in the circuit layer120. The material of the wire146may include, but is not limited to, copper (Cu), aluminum (Al), molybdenum (Mo), tungsten (W), gold (Au), chromium (Cr), nickel (Ni), platinum (Pt), titanium (Ti), an alloy of the above, a combination of the above, or any other applicable material. In some embodiments, a photolithography process is performed so that the openings are formed in the supporting structure112, and a portion of the circuit layer120is exposed. Next, the conductive material is filled into the openings. It is appreciated that the wire146may be formed before the light-emitting elements104are attached to the substrate118.

It should be noted that the wire146shown inFIG. 6Ais merely an example for better understanding the concept of the disclosure, and the scope of disclosure is not intended to be limiting. That is, the wire146may be arranged in various ways in various embodiments.

The wires121and121′ are formed in the circuit layer120, and in contact with the conductive pads106. The material of the wires121and121′ may include, but is not limited to, copper (Cu), aluminum (Al), molybdenum (Mo), tungsten (W), gold (Au), chromium (Cr), nickel (Ni), platinum (Pt), titanium (Ti), an alloy of the above, a combination of the above, or any other applicable material.

As shown inFIG. 6B, the structure200C is attached to the light-emitting elements104, in accordance with some embodiments. Next, the light filter layer130, the protective layer132and the cover layer134are formed sequentially over the structure200C, and the light-emitting device100C is created. As shown inFIG. 6B, the active element144is electrically connected to the light-emitting elements104through the wire146, the wires121,121′ and the conductive pads106. In addition, the active element144is electrically connected to the active elements and/or the passive elements formed in circuit layer120. The wires146are respectively electrically connected to a source electrode, a drain electrode and a gate electrode (not shown) of the active element144. In this embodiment, some active elements (such as the switch transistor, the driver, the reset transistor) are formed in the light blocking element122rather than circuit layer120. Therefore, the thickness may be decreased so that the size of the light-emitting device100C is reduced since the circuit layer120is thinner. In other embodiments, a passive element is electrically connected to the light-emitting element104.

Many variations and/or modifications can be made to embodiments of the disclosure. Referring toFIG. 7,FIG. 7is a cross-sectional view of a structure200D in accordance with some embodiments of the present disclosure. One of the differences between the structure200D shown inFIG. 7and the structure200C shown inFIG. 3Dis that the structure200D further includes conductive elements electrically connected to the capping layer140.

As shown inFIG. 7, the structure200D includes a source electrode150, a drain electrode152and a gate electrode154over the capping layer140, in accordance with some embodiments. At first, a source electrode150and a drain electrode152are formed on the capping layer140. Then, a gate insulating layer148is formed before the formation of the planar layer142. In some embodiments, the gate insulating layer148is made of silicon oxide or another dielectric material. Next, a conductive material is deposited on the gate insulating layer148and then patterned to form the gate electrode154. The material of the gate electrode154may include metal or another conductive material. After the gate electrode154is formed, the planar layer142is deposited over the gate electrode154and the gate insulating layer148. Next, a photolithography process is performed so that the openings are formed in the planar layer142and the gate insulating layer148, and a portion of the surface of the source electrode150, the drain electrode152, and the gate electrode154is exposed. Next, the conductive material is filled into the openings to contact the source electrode150, the drain electrode152, and the gate electrode154. The material of the source electrode150, the drain electrode152, and the gate electrode154may include, but is not limited to, copper, aluminum, tungsten, gold, chromium, nickel, platinum, titanium, iridium, rhodium, an alloy of the above, a combination of the above, or any other applicable conductive material.

As shown inFIG. 7, the capping layer140is in contact with the source electrode150and the drain electrode152. Moreover, the gate electrode154is separated from the capping layer140by the gate insulating layer148. In some embodiments, the capping layer140is made of amorphous silicon, poly-silicon, or metal oxide semiconductor. Therefore, the capping layer140may be electrically connected to the source electrode150and the drain electrode152. As a result, the structure200D may be used as a switch to control the light-emitting device. In some embodiments, the structure200C of the light-emitting device100C is replaced by the structure200D shown inFIG. 7in an upside down manner, such that the wires146are electrically connected to the source electrode150, the drain electrode152, and the gate electrode154through the conductive material filled in the openings respectively.

Many variations and/or modifications can be made to embodiments of the disclosure.FIG. 8is a cross-sectional view of a light-emitting device100D in accordance with some embodiments of the present disclosure. One of the differences between the light-emitting device100D shown inFIG. 8and the light-emitting device100A shown inFIG. 1Gis that the light-emitting device100D further includes a conductive film156disposed between the light-emitting elements104and the circuit layer120.

As shown inFIG. 8, an active element162and a wire164are formed in the circuit layer120. The circuit layer120is disposed on the substrate118. Thus, the active element162is disposed on the substrate118. The active element162may include a thin film transistor such as a switch transistor, a driver, a reset transistor, or another active element. The material of the wire164may be similar to or the same as that of the wire146, and is not repeated herein. In some embodiments, the conductive film156is an anisotropic conductive film (ACF) which includes a plurality of conductive particles158and an adhesive layer160. The conductive particle158may include metal or another conductive material. The adhesive layer160may include optical adhesive (OCA), optical clear resin (OCR), or another suitable material. As shown inFIG. 8, the conductive particles158are arranged vertically. Since the adhesive layer160is made of insulation material, the conductive film156only provides a vertical electrically conductive path. As shown inFIG. 8, the light-emitting elements104are electrically connected to the active element162through the conductive pads106, the conductive particle158and the wire164. The use of the conductive film156assists in the mass production of light-emitting devices100D.

Many variations and/or modifications can be made to embodiments of the disclosure.FIG. 9is a cross-sectional view of a light-emitting device100E in accordance with some embodiments of the present disclosure. One of the differences between the light-emitting device100E shown inFIG. 9and the light-emitting device100A shown inFIG. 1Gis that a plurality of scattering particles166are formed in the protective layer132.

The material of the scattering particle166includes, but is not limited to, titanium dioxide (TiO2), alumina trioxide (Al2O3), zirconium dioxide (ZrO2), silicon dioxide (SiO2), tantalum pentoxide (Ta2O5), tungsten oxide (WO3), yttrium oxide (Y2O3), cerium dioxide (CeO2), antimony trioxide (Sb2O3), niobium dioxide (Nb2O2), boron trioxide (B2O3), zinc oxide (ZnO), indium trioxide (In2O3), cerium trifluoride (CeF3), magnesium difluoride (MgF2), calcium difluoride (CaF2), a combination thereof, or another suitable nanoparticle. The formation of the scattering particle166in the protective layer132can assist in forming a light-emitting device100E with uniform light-extraction.

Many variations and/or modifications can be made to embodiments of the disclosure.FIG. 10is a cross-sectional view of a light-emitting device100F in accordance with some embodiments of the present disclosure. One of the differences between the light-emitting device100F shown inFIG. 10and the light-emitting device100A shown inFIG. 1Gis that a microstructure168is formed on the top surface of the protective layer132.

In some embodiments, the microstructure168may be a rough surface formed on the protective layer132. In this embodiment, the microstructure168is formed by performing an etching process or a mechanical abrasion on the top surface of the protective layer132. In some embodiments, the microstructure168includes multiple micro lenses. The formation of the microstructure168can assist in forming a light-emitting device100G with a greater angle of scattering light.

Many variations and/or modifications can be made to embodiments of the disclosure.FIG. 11is a cross-sectional view of a light-emitting device100G in accordance with some embodiments of the present disclosure. One of the differences between the light-emitting device100G shown inFIG. 11and the light-emitting device100A shown inFIG. 1Gis that the light-emitting device100G further includes a transflective layer170formed between the light-emitting elements104and the color conversion elements124,126and128.

In some embodiments, the transflective layer170is a distributed Bragg reflector (DBR) structure. The transflective layer170may include at least two materials with different refractive index. For example, the transflective layer170may include a plurality of silicon oxide films and a plurality of silicon nitride films. These silicon oxide films and silicon nitride films are arranged alternatively. In some embodiments, the material of the transflective layer170also includes silicon oxynitride or another dielectric material. The formation of the transflective layer170can assist in improving the light-emitting efficiency of the light-emitting device100G.

Many variations and/or modifications can be made to embodiments of the disclosure. Referring toFIG. 12,FIG. 12is a cross-sectional view of a light-emitting device100H in accordance with some embodiments of the present disclosure. One of the differences between the light-emitting device100H shown inFIG. 12and the light-emitting device100G shown inFIG. 11is that the transflective layer170′ is surrounded by the light blocking element122. The formation of the transflective layer170′ can assist in reducing the size of the light-emitting device100H.