A light-emitting element comprises a substrate, a plurality of light shielding layers, a capping layer, a conductive layer and a plurality of protrusions. The plurality of light shielding layers is under the substrate. The capping layer contacts a first surface of the substrate and covers the plurality of light shielding layers. The conductive layer contacts a second surface of the substrate. The plurality of protrusions is arranged on the second surface of the substrate and covers a part of the conductive layer, and an organic light-emitting unit comprising an organic material is disposed between two adjacent protrusions of the plurality of protrusions. One of the plurality of protrusions has an edge, which is offset from an edge of one of the plurality of light shielding layers in the longitudinal direction from each other.

FIELD OF THE PRESENT DISCLOSURE

The present disclosure relates to a light-emitting element and, in particular, to an organic light-emitting element.

DESCRIPTION OF THE PRIOR ART

The organic light emitting display (OLED) has been widely used in the most high-end electronic devices. However, due to the limitations of the prior art, the luminous effect of the luminescent material in the OLED cannot be effectively controlled, resulting in problems such as halo and optical crosstalk, and the optical effect of the OLED is not as expected. In the prior art, sometimes additional polarizers are added to improve the above problems, but the halo cannot be effectively eliminated, and the additional polarizers have disadvantages such as increasing the thickness of the display and high cost. The present disclosure provides a device that can solve the above-mentioned dilemma.

SUMMARY OF THE PRESENT DISCLOSURE

In the present disclosure, a light-emitting element is provided. The light-emitting element comprises a substrate, a plurality of light shielding layers, a capping layer, a conductive layer and a plurality of protrusions. The plurality of light shielding layers is disposed under the substrate. The capping layer contacts a first surface of the substrate and covers the plurality of light shielding layers. The conductive layer contacts a second surface of the substrate. The plurality of protrusions is disposed on the second surface of the substrate and covers a part of the conductive layer, and an organic light-emitting unit comprising an organic material is disposed between two adjacent protrusions of the plurality of protrusions. One of the plurality of protrusions has an edge, which is offset from an edge of one of the plurality of light shielding layers in the longitudinal direction.

In some embodiments, an area of each of the plurality of light shielding layers in the lateral direction is larger than an area of each of the plurality of protrusions.

In some embodiments, the conductive layer includes a transparent conductive film, and the transparent conductive film includes ITO (indium tin oxide), IZO (indium zinc oxide) or IGZO (indium gallium zinc oxide).

In some embodiments, the light-emitting element comprises a release layer under the capping layer, wherein the release layer is separated from the plurality of light shielding layers by the capping layer.

In some embodiments, a distance between respective edges of the two adjacent protrusions of the organic light-emitting unit is greater than a distance between respective edges of two adjacent light shielding layers in the plurality of light shielding layers.

In some embodiments, one of the plurality of light shielding layers includes a depression having a cross-shaped profile that exposes light emitted by a single organic light-emitting unit.

In some embodiments, one of the plurality of light shielding layers include a depression having a cross-shaped profile that exposes light emitted by a plurality of organic light-emitting units.

In the present disclosure, a light-emitting element is provided. The light-emitting element includes a substrate, a patterned light shielding layer, a capping layer, a plurality of protrusions and a release layer. The patterned light shielding layer is disposed under the substrate and has an opening. The capping layer is disposed under the patterned light shielding layer. The plurality of protrusions arranged on the substrate, an organic light-emitting unit containing an organic light-emitting material being disposed between two adjacent protrusions of the plurality of protrusions, wherein the organic light-emitting unit includes a first light-emitting unit, a second light-emitting unit and a third light-emitting unit, wherein an edge of the patterned light shielding layer is not aligned with an edge of one of the plurality of protrusions. The release layer is disposed under the capping layer, wherein the release layer and the patterned light shielding layer are separated by the capping layer.

In some embodiments, the organic light-emitting material includes a molecular structure with a resonance structure, and can be selected from the group consisting of a spiro-triarylamine, a bis-triarylamine and a combination thereof.

In some embodiments, the first light-emitting unit, the second light-emitting unit and the third light-emitting unit each have an effective light-emitting area whose size is defined by an anode located under each light-emitting unit, each light-emitting unit having a black area and a bright area when emitting light, wherein a total area of the black area is less than 50% of the effective light-emitting area.

In some embodiments, the first light-emitting unit, the second light-emitting unit and the third light-emitting unit each have an organic light-emitting stack layer containing an organic material, wherein the organic light-emitting stack layer includes: a carrier injection layer; a carrier transport layer; an organic emission layer; and an organic carrier transfer layer.

In some embodiments, the light shielding layer and the capping layer include an organic material, and the release layer includes an inorganic material.

In some embodiments, the substrate comprises a transparent material.

In some embodiments, a distance between respective edges of two adjacent protrusions of the first light emitting unit is greater than a width of the opening of the patterned light shielding layer.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG.1is a top view illustrating an intermediate product of a light-emitting element10. The light-emitting element10has a light-emitting layer20and a capping layer40disposed over the light-emitting layer20. For the light-emitting layer20, a spacer21can be designed to provide an array of recesses for accommodating an array of light-emitting pixels. In some embodiments, the spacer21may comprise a photosensitive material.

FIG.2is an illustration of a cross-sectional view along line AA inFIG.1and illustrates only a light-emitting region. For simplicity, the covering layer40is omitted here. The spacer21has a plurality of protrusions105to define a light-emitting pixel pattern. A recess is located between two adjacent protrusions105and provides a space for accommodating a light-emitting pixel. Those skilled in the art should understand that from the cross-sectional view, the protrusions105are depicted as disconnected, but from the top view ofFIG.1, they can be connected to one another through other portions of the spacer21.

The light-emitting element10includes a light-emitting array, which includes a first organic light-emitting unit10a, a second organic light-emitting unit10band a third organic light-emitting unit10c. The organic light-emitting unit may also be referred to as a light-emitting pixel herein. In some embodiments, the light-emitting unit10aincludes a first electrode104, a carrier injection layer106L1above the protrusion105and the first electrode104, a carrier transport layer106L2above the carrier injection layer106L1, an organic emission layer106L3above a portion of the carrier transport layer106L2and an organic carrier transport layer106L4above the organic emission layer106L3. The carrier injection layer106L1, the carrier transport layer106L2, the organic emission layer106L3and the organic carrier transport layer106L4may be collectively referred to as an organic light-emitting stack layer.

In some embodiments, the carrier injection layer106L1is arranged between the first electrode104and the carrier transport layer106L2. The light-emitting unit10aincludes an organic material, which can be placed in any one of the carrier transport layer, the carrier injection layer or the organic emission layer in the light-emitting unit10aaccording to different implementations. Further, in some embodiments, the organic material has an absorption rate of greater than or equal to 50% for a specific wavelength. In some embodiments, the organic material has an absorption rate of greater than or equal to 60% for a specific wavelength. In some embodiments, the organic material has an absorption rate of greater than or equal to 70% for a specific wavelength. In some embodiments, the organic material has an absorption rate of greater than or equal to 80% for a specific wavelength. In some embodiments, the organic material has an absorption rate of greater than or equal to 90% for a specific wavelength. In some embodiments, the organic material has an absorption rate of greater than or equal to 95% for a specific wavelength.

In some embodiments, the specific wavelength is not greater than 400 nm. In some embodiments, the specific wavelength is not greater than 350 nm. In some embodiments, the specific wavelength is not greater than 300 nm. In some embodiments, the specific wavelength is not greater than 250 nm. In some embodiments, the specific wavelength is not greater than 200 nm. In some embodiments, the specific wavelength is not greater than 150 nm. In some embodiments, the specific wavelength is not greater than 100 nm.

The substrate100is located under the light-emitting layer20. In some embodiments, the substrate100may include a thin film transistor (TFT) array. In some embodiments, the substrate100includes a base (not shown), a dielectric layer (not shown) and one or more circuits (not shown) disposed on or in the base. In some embodiments, the base is a transparent base, or is at least partially transparent. In some embodiments, the base is a non-flexible base, and the material of the base may include glass, quartz, low temperature poly-silicon (LTPS) or other suitable materials. In some embodiments, the base is a flexible base, and the material of the base may include transparent epoxy resin, polyimide, polyvinyl chloride, methyl methacrylate or other suitable materials. The dielectric layer may be disposed on the base as needed. In some embodiments, the dielectric layer may include silicon oxide, silicon nitride, silicon oxynitride or other suitable materials.

In some embodiments, the circuit may comprise a complementary metal-oxide-semiconductor (CMOS) circuit, or comprise a plurality of transistors and a plurality of capacitors adjacent to the transistors, wherein the transistors and capacitors are formed on the dielectric layer. In some embodiments, the transistor is a thin-film transistor (TFT). Each transistor includes source/drain regions (including at least one source region and a drain region), a channel region between the source/drain regions, a gate electrode disposed above the channel region, and a gate insulator between the channel region and the gate electrode. The channel region of the transistor may be made of a semiconductor material, such as silicon or other elements selected from Group IV or Group III and Group V.

A plurality of light shielding layers101is formed under the substrate100. The plurality of light shielding layers101is formed on a first surface100aof the substrate100. The plurality of light shielding layers101is separated from the substrate100. The plurality of light shielding layers101can also be collectively referred to as patterned light shielding layers101. The plurality of light shielding layers101is separated from one another by a distance W1. The portions that separate the plurality of light shielding layers101from one another can also be referred to as openings, and the opening has a width W1. The plurality of light shielding layers101can absorb more than 90% of visible light. In some embodiments, the light shielding layer101may comprise a black body material. In some embodiments, the light shielding layer101includes a layer of a single material. In some embodiments, the light shielding layer101includes a composite layer formed of a plurality of materials. In some embodiments, the light shielding layer101includes an organic material. In some embodiments, the light shielding layer101includes an inorganic material.

The capping layer102contacts the first surface100aof the substrate100and covers the plurality of light shielding layers101. The capping layer102is formed in the gap between the plurality of light shielding layers101. The capping layer102is formed in the openings of the patterned light shielding layer101. The capping layer102covers the lower surface and two side surfaces of the light shielding layer101. The capping layer102separates the substrate100from the plurality of light shielding layers101. In some embodiments, capping layer102includes an organic material. In some embodiments, the capping layer102can protect the light shielding layer101from being scratched during the manufacturing process.

A plurality of first electrodes104is formed on a second surface100bof the substrate100. The plurality of first electrodes104is in contact with the substrate100. The plurality of first electrodes104is in contact with the second surface100bof the substrate100. The plurality of first electrodes104is separated from one another. The plurality of first electrodes104is electrically connected to the substrate100.

As shown inFIG.2, a plurality of protrusions105is arranged on the second surface of the substrate100and cover a part of the first electrode104. The peripheral area of the first electrode104is covered by the protrusion105. In some embodiments, the edge corners of the first electrode104are completely surrounded by the protrusion105. In some embodiments, the sidewall of the first electrode104is completely in contact with the protrusion105. In some embodiments, two protrusions105in the gaps between two first electrodes104are separated from each other.

In this case, the first electrode104may be an anode. In this case, the first electrode104can be a conductive layer. The first electrode104of the light-emitting unit10acan define the size of the effective light-emitting area. In some examples, the light-emitting unit10ahas a black area and a bright area when emitting light. The total area of the black area is less than 50% of the effective light-emitting area. The effective light-emitting area can also be called the effective illumination area.

In some embodiments, the effective illumination area has a width of at least less than 10 microns. In some embodiments, the effective illumination area has a width of about 3 microns to 6 microns. In some embodiments, the effective illumination area has a width of about 4 microns to 6 microns. The effective illumination area determines the pixel size of the light-emitting element10inFIG.1. Since the size of the effective illumination area can be controlled below 10 microns, the pixel density of the light-emitting element10can exceed 1000 or 2000 ppi.

InFIG.2, the light shielding layer101has a thickness101T. The first electrode104has a thickness104T. In some embodiments, the thickness101T of the light shielding layer101is greater than the thickness104T of the first electrode104. In some embodiments, the thickness101T of the light shielding layer101is equal to the thickness104T of the first electrode104. In some embodiments, the thickness101T of the light shielding layer101is smaller than the thickness104T of the first electrode104.

The first electrode104may have a total thickness of about 1500 Å to about 2700 Å. In some embodiments, the first electrode104has a total thickness of about 1800 Å to about 2200 Å. In some embodiments, the first electrode104has a total thickness of about 2000 Å. The first electrode104can be an electrically conductive layer. The first electrode104may comprise ITO, IZO, IGZO, AlCu alloy, AgMo alloy, about 50 Å to 500 Å ITO (or IZO or IGZO) and 500 Å to 2000 Å metal film (Ag, Al, Mg, Au) and about 50 Å to 1000 Å ITO (or IZO or IGZO).

In some embodiments, the electrode104is a composite structure. For example, the electrode104has a conductive film and a transparent conductive film located thereon. The conductive film is located between the transparent conductive film and the substrate100. In some embodiments, the conductive film includes aluminum, gold, silver, copper, or the like. In some embodiments, the transparent conductive film includes indium, tin, graphene, zinc, oxygen, and the like. In some embodiments, the electrode104includes a transparent conductive thin film. In some embodiments, the electrode104includes ITO (indium tin oxide). In some embodiments, the electrode104includes IZO (indium zinc oxide). In some embodiments, the electrode104includes IGZO (indium gallium zinc oxide). In some embodiments, a roughness Ra of the transparent conductive film is less than 10 Å. A thickness of the conductive film may range from about 1500 Å to about 3000 Å. A thickness of the transparent conductive film may be between about 80 Å and about 1000 Å.

In some embodiments, the first electrode104has at least three different films. A conductive film (such as Al, Cu, Ag, Au, etc.) is sandwiched between two transparent conductive films. In some circumstances, one of the two transparent conductive films is ITO, one side of which is in contact with the substrate100and the other side is in contact with the conductive film. In some circumstances, one of the two transparent conductive films is ITO, one side of which is in contact with the conductive film and the other side is in contact with the protrusion105or the light-emitting material.

In some embodiments, each protrusion105has a curved surface protruding away from the substrate100and covering a peripheral area of the first electrode104. The protrusions105can be of different shapes. In some embodiments, the protrusion105has a curved surface. In some embodiments, the protrusion105is trapezoidal in shape. In some embodiments, the protrusion105is rectangular in shape. The pattern of the protrusion105is designed according to the pixel arrangement, and the patterned protrusion105may be called a pixel defined layer (PDL). The protrusions105are arranged over the substrate100. Each protrusion105fills the gap between two adjacent first electrodes104. Each first electrode104is partially covered by a protrusion105. The protrusions105may include the photosensitive material. InFIG.2, the area of each of the plurality of light shielding layers101is larger than the area of each of the protrusions105in the lateral direction.

One of the protrusions105has an edge105aon an upper surface thereof covering the first electrode104. The light shielding layer101has an edge101anear the center of the first electrode104. The edge101aof the light shielding layer101is not aligned with the edge105aof the protrusion105. An offset d exists between the edge105aof the protrusion105and the edge101aof the light shielding layer in the longitudinal direction. The percentage of the offset d to the width of the light shielding layer101may be greater than or equal to 1%. The percentage of the offset d to the width of the light shielding layer101may be greater than or equal to 5%. The percentage of the offset d to the width of the light shielding layer101may be greater than or equal to 10%. The percentage of the offset d to the width of the light shielding layer101may be greater than or equal to 15%.

One of the protrusions105′ has an edge105′aon an upper surface thereof covering the first electrode104. The light shielding layer101′ has an edge101′anear the center of the first electrode104. The edge101′aof the light shielding layer101′ is not aligned with the edge105′aof the protrusion105′. An offset d′ exists between the edge105′aof the protrusion105′ and the edge101′aof the light shielding layer. The percentage of the offset d′ to the width of the light shielding layer101′ may be greater than or equal to 1%. The percentage of the offset d′ to the width of the light shielding layer101′ may be greater than or equal to 5%. The percentage of the offset d′ to the width of the light shielding layer101′ may be greater than or equal to 10%. The percentage of the offset d′ to the width of the light shielding layer101′ may be greater than or equal to 15%. In some embodiments, the offset d is equal to the offset d′. In some embodiments, the offset d is greater than the offset d′. In some embodiments, the offset d is less than the offset d′.

InFIG.2, the distance between the plurality of light shielding layers101and101′ is W1, and the distance between the respective edges105aand105′aof two adjacent protrusions105and105′ is W2. Due to the offset d and d′, the distance W2between the respective edges105aand105′aof two adjacent protrusions105and105′ is greater than the distance W1between the respective edges101aand101′aof the two adjacent light shielding layers101and101′ among the plurality of light shielding layers. InFIG.2, the distance W2between the respective edges105aand105′aof two adjacent protrusions105and105′ may be the sum of the distance W1between the two light shielding layers101and101′ among the plurality of light shielding layers101, the offset d and the offset d′. The distance W2between the respective edges105aand105′aof two adjacent protrusions105and105′ can define the area of the effective light-emitting region. Because the distance W1between the light shielding layers101and101′ is smaller than the distance W2, the light shielding layers101and101′ can control the light emitted by the first electrode104, thereby improving the imaging effect of the pattern.

In some embodiments, the absorption rate of the protrusion105for a specific wavelength is greater than or equal to 50%. In some embodiments, the absorption rate of the protrusion105for a specific wavelength is greater than or equal to 60%. In some embodiments, the absorption rate of the protrusion105for a specific wavelength is greater than or equal to 70%. In some embodiments, the absorption rate of the protrusion105for a specific wavelength is greater than or equal to 80%. In some embodiments, the absorption rate of the protrusion105for a specific wavelength is greater than or equal to 90%. In some embodiments, the absorption rate of the protrusion105for a specific wavelength is greater than or equal to 95%. In some embodiments, the specific wavelength is not greater than 400 nm. In some embodiments, the specific wavelength is not greater than 350 nm. In some embodiments, the specific wavelength is not greater than 300 nm. In some embodiments, the specific wavelength is not greater than 250 nm. In some embodiments, the specific wavelength is not greater than 200 nm. In some embodiments, the specific wavelength is not greater than 150 nm. In some embodiments, the specific wavelength is not greater than 100 nm.

The carrier injection layer106L1is disposed on the exposed surfaces of the capping layer102, the protrusion105and the first electrode104. The carrier injection layer106L1continuously covers the exposed surfaces of the protrusion105and the first electrode104. In some embodiments, the exposed surface of each first electrode104is configured for an effective light-emitting area of one light-emitting unit10a. Optionally, the carrier injection layer106L1is in contact with the protrusion105. In some embodiments, the carrier injection layer106L1is in contact with the first electrode104. In some embodiments, the carrier injection layer106L1is an organism. In some embodiments, the carrier injection layer106L1is configured to perform hole injection. In some embodiments, the carrier injection layer106L1is a hole injection layer. In some embodiments, the carrier injection layer106L1may have a thickness of about 80 Å to about 500 Å.

The carrier transport layer106L2is disposed on the exposed surfaces of the capping layer102, the protrusion105and the first electrode104. The carrier transport layer106L2is disposed above the carrier injection layer106L1and completely covers the carrier injection layer106L1. The carrier injection layer106L1is disposed under the carrier transport layer106L2. The carrier transport layer106L2continuously covers the carrier injection layer106L1. The carrier transport layer106L2covers the plurality of protrusions105and the plurality of first electrodes104. Optionally, the carrier transport layer106L2is in contact with the carrier injection layer106L1. In some embodiments, the carrier transport layer106L2is an organism. In some embodiments, carrier transport layer106L2is configured to perform hole transport. In some embodiments, the carrier transport layer106L2is a first hole transport layer. In some embodiments, the carrier injection layer106L1may have a thickness of about 80 Å to about 500 Å.

The organic emission layer106L3is disposed on the exposed surfaces of the capping layer102, the protrusion105and the first electrode104. The organic emission layer106L3is disposed above the carrier transport layer106L2and completely covers the carrier transport layer106L2. The carrier transport layer106L2is disposed under the organic emission layer106L3. The organic emission layer106L3continuously covers the carrier transport layer106L2. The organic emission layer106L3covers the plurality of protrusions105and the plurality of first electrodes104. Optionally, the organic emission layer106L3is in contact with the carrier transport layer106L2. The organic emission layer106L3is configured to emit a first color.

In some embodiments, the absorption rate of the organic emission layer106L3for a specific wavelength is greater than or equal to 50%. In some embodiments, the absorption rate of the organic emission layer106L3for a specific wavelength is greater than or equal to 60%. In some embodiments, the absorption rate of the organic emission layer106L3for a specific wavelength is greater than or equal to 70%. In some embodiments, the absorption rate of the organic emission layer106L3for a specific wavelength is greater than or equal to 80%. In some embodiments, the absorption rate of the organic emission layer106L3for a specific wavelength is greater than or equal to 90%. In some embodiments, the absorption rate of the organic emission layer106L3for a specific wavelength is greater than or equal to 95%. In some embodiments, the specific wavelength is not greater than 400 nm. In some embodiments, the specific wavelength is not greater than 350 nm. In some embodiments, the specific wavelength is not greater than 300 nm. In some embodiments, the specific wavelength is not greater than 250 nm. In some embodiments, the specific wavelength is not greater than 200 nm. In some embodiments, the specific wavelength is not greater than 150 nm. In some embodiments, the specific wavelength is not greater than 100 nm.

In some embodiments, at least one of the carrier transport layer106L2and the organic emission layer106L3includes an organic material. The organic material may include a molecular structure having a resonance structure. The organic material may be selected from the group consisting of a spiro-triarylamine, a bis-triarylamine and a combination thereof. In some embodiments, at least one of the carrier transport layer106L2and the organic emission layer106L3includes the spiro-triarylamine. In some embodiments, at least one of the carrier transport layer106L2and the organic emission layer106L3includes the bis-triarylamine. In some embodiments, the carrier transport layer106L2and the organic emission layer106L3comprise the same material. In some embodiments, the carrier transport layer106L2includes

and the organic emission layer106L3includes

In some embodiments, the carrier transport layer106L2includes

and the organic emission layer106L3includes

The organic carrier transport layer106L4is disposed on the exposed surfaces of the capping layer102, the protrusion105and the first electrode104. The organic carrier transport layer106L4is disposed on the organic emission layer106L3and completely covers the organic emission layer106L3. The organic emission layer106L3is disposed under the organic carrier transport layer106L4. The organic carrier transport layer106L4continuously covers the organic emission layer106L3. The organic carrier transport layer106L4covers the plurality of protrusions105and the plurality of first electrodes104. Optionally, the organic carrier transport layer106L4is in contact with the organic emission layer106L3.

The second electrode106D is disposed on the exposed surfaces of the capping layer102, the protrusion105and the first electrode104. The second electrode106D is located above the organic carrier transport layer106L4and completely covers the organic carrier transport layer106L4. In some circumstances, the second electrode106D is patterned to cover only the effective light-emitting area of each light-emitting pixel. In some circumstances, the second electrode106D is in contact with the organic carrier transport layer106L4.

The second electrode106D may have a thickness of about 80 Å to about 500 Å. In some embodiments, the second electrode106D may have a thickness of about 80 Å to about 150 Å. In some embodiments, the second electrode106D may have a thickness of about 150 Å to about 200 Å. In some embodiments, the second electrode106D may have a thickness of about 200 Å to about 300 Å. In some embodiments, the second electrode106D may have a thickness of about 300 Å to about 400 Å. In some embodiments, the second electrode106D may have a thickness of about 400 Å to about 500 Å.

In this case, the second electrode106D may be a cathode. The second electrode106D can be a metal material, such as Ag, Mg and the like. In some embodiments, the second electrode106D includes ITO (indium tin oxide) or IZO (indium zinc oxide).

In some embodiments, the second electrode106D is a composite structure. For example, the second electrode106D has a conductive film and a transparent conductive film thereon. The conductive film is located between the transparent conductive film and the organic carrier transport layer106L4. In some embodiments, the conductive film includes aluminum, gold, silver, copper, magnesium, molybdenum, and the like. In some embodiments, the transparent conductive film includes indium, tin, graphene, zinc, oxygen, and the like. In some embodiments, the transparent conductive film is ITO (indium tin oxide). In some embodiments, the transparent conductive film is IZO (indium zinc oxide). In some embodiments, the transparent conductive film is located between the conductive film and the organic carrier transport layer106L4. In some embodiments, the second electrode106D can be a patterned conductive layer, or a patterned conductive layer with a patterned insulating layer.

InFIG.2, the light-emitting element10includes a substrate100, a plurality of protrusions105on the substrate100and a plurality of light-emitting units separated by the protrusions105.

These light-emitting units include a first light-emitting unit10a, a second light-emitting unit10band a third light-emitting unit10c. In some embodiments, the first light-emitting unit10a, the second light-emitting unit10band the third light-emitting unit10care adjacent to one another. In some embodiments, the second light-emitting unit10band the third light-emitting unit10chave a structure similar to that of the first light-emitting unit10a. In addition, although the first light-emitting unit10a, the second light-emitting unit10band the third light-emitting unit10care illustrated as having similar features, this is merely exemplary and not intended to limit these embodiments. The first light-emitting unit10a, the second light-emitting unit10band the third light-emitting unit10cmay have similar structures or different structures to meet desired functional requirements.

The first light-emitting unit10a, the second light-emitting unit10band the third light-emitting unit10cmay be different from one another at least in the thickness of the organic light-emitting stack layer. In some embodiments, the first light-emitting unit10aemits green light, the second light-emitting unit10bemits red light, and the third light-emitting unit10cemits blue light.

In some embodiments, the light-emitting units10a,10b,10care configured to be divided into at least three different groups, wherein each group emits a different color than the other groups. The thickness of each organic light-emitting stack layer may be related to the color displayed by the corresponding light-emitting unit10a,10b,10c. In some embodiments, the first light-emitting unit10aemits green light compared to other light-emitting units configured to emit a different color, and the organic light-emitting stack layer of the first light-emitting unit10amay have a minimum thickness. In some embodiments, compared with other light-emitting units configured to emit different colors, the second light-emitting unit10bemits red light, and the thickness of the organic light-emitting stack layer in the second light-emitting unit10bmay be between the thickness of the organic light-emitting stack layer in the first light-emitting unit10aand the thickness of the organic light-emitting stack layer in the third light-emitting unit10c. In some embodiments, the third light-emitting unit10cemits blue light compared to other light-emitting units configured to emit different colors, and the organic light-emitting stack layer of the third light-emitting unit10cmay have a maximum thickness. The organic light-emitting stack layers of the first light-emitting unit10a, the second light-emitting unit10band the third light-emitting unit may be formed through various processes such as vapor deposition, liquid jetting or inkjet printing.

In some embodiments, the first, second and third light-emitting units10a,10b, may differ from one another at least in the thickness difference of the carrier transport layer of the first, second and third light-emitting units10a,10b,10c.

In some embodiments, the light-emitting units10a,10b,10care configured to be divided into at least three different groups, wherein each group emits a different color than the other groups. The thickness of the carrier transport layer can be correlated to the color displayed by the respective light-emitting unit10a. In some embodiments, the first light-emitting unit10aemits green light compared to other light-emitting units configured to emit a different color, and the carrier transport layer of the first light-emitting unit10amay have a minimum thickness. In some embodiments, the second light-emitting unit10bemits red light compared to other light-emitting units configured to emit a different color, and the thickness of the carrier transport layer in the second light-emitting unit10bmay be between the thickness of the carrier transport layer in the first light-emitting unit10aand the thickness of the carrier transport layer in the third light-emitting unit10c. In some embodiments, the third light-emitting unit10cemits blue light compared to other light-emitting units configured to emit a different color, and the carrier transport layer of the third light-emitting unit10cmay have a maximum thickness.

FIG.3is a cross-sectional view showing the relative relationship between the light-emitting element and the debonding film. The release layer103is formed under the capping layer102. In some embodiments, the release layer103can protect the capping layer102. In some embodiments, the capping layer102can protect the light shielding layer101. In some embodiments, the release layer103can protect the light shielding layer101. The release layer103is separated from the plurality of light shielding layers101by the capping layer102. In some embodiments, the release layer103includes an inorganic material. In some embodiments, the release layer103includes silicon oxide or silicon nitride. In some embodiments, the release layer103may include silicon.

During the manufacturing process, a debonding film107is provided to fix the plurality of light-emitting elements10′. As the relative positional relationship shown inFIG.3, the release layer103is formed between the capping layer102and the debonding film107, and the release layer103is in contact with the debonding film107. The debonding film107is used to fix a wafer on which the light-emitting elements are formed, so as to ensure cutting accuracy when dividing the light-emitting elements. After the cutting is completed, the light-emitting element10′ is separated from the debonding film107. In some embodiments, the debonding film107comprises an organic material. When the light-emitting element10′ and the debonding film107are separated by irradiating ultraviolet light, since the release layer103is an inorganic material and the debonding film107is an organic material, the release layer103and the debonding film107are easily peeled off, thereby improving the process yield when dividing the light-emitting element10′. In some embodiments, the release layer103can achieve the technical effect of easy peeling. In some embodiments, the release layer103can protect the light shielding layer101. In some embodiments, the release layer103includes a scratch-resistant material. In some embodiments, the release layer103prevents the light shielding layer101from diffusing.

In some embodiments, the release layer103includes a layer of a single material. In some embodiments, the release layer103includes a composite layer formed of a plurality of materials. In some embodiments, the release layer103can be coated or sprayed on the capping layer102. In some embodiments, the thickness of the release layer103may be less than 15 μm, for example, between 1 μm and 10 μm. In some embodiments, the release layer103may include a photoresist material, such as carbon, hydrogen, oxygen, other suitable materials, or a mixture of a combination thereof. In some embodiments, one side surface of the release layer103may be coated with a release agent with separation property. In some embodiments, the release force of the release layer103may be less than 15 grams/millimeter (g/mm), such as less than 10 g/mm.

FIG.4AtoFIG.4Kdepict a method of manufacturing a light-emitting element according to an embodiment.

InFIG.4B, a plurality of light shielding layers101is disposed on the first surface100aof the substrate100. Each light shielding layer101is arranged on the same side of the substrate. The respective light shielding layers101are separated from one another.

InFIG.4C, a capping layer102is disposed on each light shielding layer101on the first surface100aof the substrate100. The capping layer102surrounds the upper surface and two side surfaces of each of the plurality of light shielding layers101. The capping layer102contacts the substrate100. The capping layer102is formed on the plurality of light shielding layers101through one of chemical vapor deposition (CVD), physical vapor deposition (PVD) and spin-on-glass (SOG) spin coating.

InFIG.4D, a plurality of first electrodes104is disposed on the second surface100bof the substrate100. Each first electrode104is configured to be electrically connected to the substrate100. The array pattern of the first electrodes104is designed in consideration of the arrangement of pixels.

InFIG.4E, a photosensitive layer105L is provided on the first electrode104. In some embodiments, the photosensitive layer105L is coated on the first electrode104and the capping layer102. The photosensitive layer105L fills in the gap between adjacent first electrodes104. The photosensitive layer105L is heated to a predetermined temperature and then exposed to a specified wavelength. The photosensitive layer105L can absorb more than 90% of visible light. After exposure, the photosensitive layer105L is wetted in a solution for development.

As shown inFIG.4F, a portion of the photosensitive layer105L is removed, and the remaining portion partially covers the gap between adjacent first electrodes104. In this cross-sectional view, the remaining photosensitive layer105L forms a plurality of protrusions105, and each protrusion105is formed on part of the upper surface of the first electrode104and covers one side surface of the first electrode104. The protrusions105partially cover the respective first electrodes104.

The protrusions105may be formed in different shapes. InFIG.4F, the protrusion105has a curved surface. In some embodiments, the protrusion105is trapezoidal in shape. After the protrusions105are formed, a cleaning operation is performed to clean the exposed surfaces of the protrusions105and the first electrodes104. In one embodiment, the deionized water is heated to a temperature between 30° C. and 80° C. during the cleaning operation. After the temperature of the deionized water is raised to a predetermined temperature, the deionized water is introduced to the exposed surfaces of the protrusions105and the first electrodes104.

In some embodiments, ultrasound is used during the cleaning operation. Ultrasound is introduced into a cleaning agent (such as water or isopropyl alcohol (IPA), etc.). In some embodiments, carbon dioxide is introduced into the cleaning agent. After the cleaning operation, the cleaning agent is removed from the exposed surfaces through a heating operation. During the heating operation, the substrate100and protrusions105may be heated to a temperature between 80° C. and 110° C. In some instances, compressed air is directed to the exposed surface to help remove the residue of the cleaning agent while heating.

After the heating operation, the exposed surfaces can be treated with O2, N2, or Ar plasma. Plasma is used to roughen the exposed surfaces. In some embodiments, ozone is used to condition the surface state of the exposed surfaces.

As shown inFIG.4G, the carrier injection layer106L1is disposed on the protrusion105, a part of the exposed surface of the capping layer102and the exposed surface of the first electrode104. The carrier injection layer106L1is continuously lining along the exposed surface. More specifically, the exposed surface of each first electrode104is configured as an effective light-emitting area of a light-emitting unit (i.e., a pixel). In this embodiment, all light-emitting units use the carrier injection layer106L1. In some embodiments, the carrier injection layer106L1is used for hole injection. In some embodiments, the carrier injection layer106L1is used for electron injection. The carrier injection layer106L1continuously covers the exposed surfaces of the plurality of protrusions105and the first electrodes104. Optionally, the carrier injection layer106L1is in contact with the protrusion105. In one embodiment, the carrier injection layer106L1is in contact with the first electrode104. In some embodiments, the carrier injection layer106L1is organic.

As shown inFIG.4H, a carrier transport layer106L2is disposed on the protrusion105, a part of the exposed surface of the capping layer102and the exposed surface of the first electrode104. The carrier injection layer106L1is disposed below the carrier transport layer106L2. The carrier transport layer106L2is continuously lining along the carrier injection layer106L1. In this embodiment, all the light-emitting units use the carrier transport layer106L2. In some embodiments, the carrier transport layer106L2is used for hole injection. In some embodiments, the carrier transport layer106L2is used for electron injection. The carrier transport layer106L2continuously covers the plurality of protrusions105and the first electrodes104. Optionally, the carrier transport layer106L2is in contact with the carrier injection layer106L1. In some embodiments, the carrier transport layer106L2is organic.

InFIG.4I, the organic emission layer106L3is disposed on the protrusion105, a portion of the exposed surface of the capping layer102and the exposed surface of the first electrode104. The organic emission layer106L3covers the carrier transport layer106L2. The organic emission layer106L3completely covers the exposed carrier transport layer106L2. The organic emission layer106L3is configured to emit a first color.

As shown inFIG.4J, an organic carrier transport layer106L4is disposed on the organic emission layer106L3. The organic carrier transport layer106L4can be a hole or electron transport layer. In some embodiments, the organic carrier transport layer106L4and the carrier transport layer106L2are respectively configured in opposite valence states.

InFIG.4K, a second electrode106D is disposed on the organic carrier transport layer106L4. The second electrode106D covers the organic carrier transport layer106L4. The second electrode106D can be a metal material, such as Ag, Mg and the like. In some embodiments, the second electrode106D includes ITO (indium tin oxide) or IZO (indium zinc oxide). In some embodiments, each light-emitting unit (i.e., pixel) has an independent second electrode106D from a cross-sectional view.

The operations shown inFIG.4AtoFIG.4Kcan be repeatedly performed to form light-emitting units of different colors.

As shown inFIG.4K, the light L1generated by the light-emitting unit can be emitted outwards towards the substrate, and part of the light L2can also be emitted outwards towards the second electrode106D. When the light L2hits the second electrode106D, a different reflected light L2rmay be generated due to different materials in the second electrode106D. The reflected light L2rmay interfere with the light L1generated by the light-emitting unit, thus causing problems such as halo and optical crosstalk, resulting in an unsatisfactory optical effect of the organic light-emitting display. According to the light shielding layer101of the present disclosure, through proper configuration (for example, using the above discussion to shield the ambient light), the interference of the reflected light L2ron the light L1can be greatly reduced, thereby solving problems such as halo and optical crosstalk, and improving the contrast of the light-emitting unit.

Referring toFIG.5A, in some embodiments, the light shielding layer101may have a cross-shaped depression500(which may correspond to the W1portion marked inFIG.2) from a top view. The cross-shaped profile500allows the light emitted by the light-emitting unit (e.g.10a,10bor10c) to pass through. In some embodiments, the cross-shaped profile500allows the light emitted by a single light-emitting unit to pass through. In some embodiments, the cross-shaped profile500allows the light emitted by the plurality of light-emitting units to pass through.

Referring toFIG.5B, in some embodiments, the light shielding layer101may include a first depression502and second depressions504,506,508,510. The first depression502has a cross-shaped profile; the second depressions504,506,508,510are located on four sides of the first depression502, and have an L-shaped profile, so that the first depression502and the second depressions504,506,508,510together form a crosshair pattern. The crosshair pattern can allow the light emitted by the light-emitting unit (for example10a,10bor10c) to pass through. In some embodiments, the first depression502may overlap with the effective light-emitting area of a single light-emitting unit, allowing the light emitted by the single light-emitting unit to pass through. In some embodiments, the first depression502may overlap with the effective light-emitting area of a plurality of light-emitting units, allowing the light emitted by the plurality of light-emitting units to pass through. In some embodiments, each of the second depressions504,506,508,510may overlap with the effective light-emitting area of a single light-emitting unit, each allowing the light emitted by the single light-emitting unit to pass through. In some embodiments, each of the second depressions504,506,508,510may overlap with the effective light-emitting area of a plurality of light-emitting units, allowing the light emitted by the plurality of light-emitting units to pass through.

In some embodiments, the first depression502and the second depressions504,506,508,510may overlap with the effective light-emitting area of a single light-emitting unit, allowing the light emitted by the single light-emitting unit to pass through. In some embodiments, the first depression502and the second depressions504,506,508,510can overlap with the effective light-emitting areas of a plurality of light-emitting units, so that the light emitted by the plurality of light-emitting units can pass through.

The present application can adjust the patterning into a desired shape according to actual needs.

The foregoing content outlines the features of some implementations so that those skilled in the art may understand various aspects of the disclosure better. Those skilled in the art should understand that the present disclosure can be easily used as a basis for designing or modifying other processes and structures to reach the same purpose and/or achieve the same advantages as the embodiments described in this application. Those skilled in the art should also understand that this equal configuration does not depart from the spirit and scope of the disclosure, and those skilled in the art can make various changes, substitutions and replacements without departing from the spirit and scope of the disclosure.