DISPLAY DEVICE AND MANUFACTURING METHOD THEREOF

The present disclosure provides a display device and a manufacturing method thereof. The manufacturing method of the display device includes providing a first substrate, providing a second substrate, forming a plurality of spacers on the first substrate or the second substrate by a printing process, and attaching the first substrate and the second substrate to each other, wherein the first substrate and the second substrate are separated by the spacers. The first substrate includes a plurality of light-emitting elements, the second substrate includes a plurality of optical filter elements, and the light-emitting elements overlap the optical filter elements, respectively.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The present disclosure relates to a display device and a manufacturing method thereof.

2. Description of the Prior Art

With the increasing convenience of electronic devices, they have become necessary tools in people's life. However, in the conventional self-luminous electronic devices, there are still problems related to display quality. Especially, although the electronic device can directly display images through light-emitting elements, there are other layer elements disposed on the light-emitting elements. Therefore, when the uniformity of the layer elements is not good, the display quality is easily affected by the layer elements on the light-emitting elements, which results in uneven image brightness.

SUMMARY OF THE DISCLOSURE

According to some embodiments, the present disclosure discloses a manufacturing method of a display device. The manufacturing method includes providing a first substrate, providing a second substrate, forming a plurality of spacers on the first substrate or the second substrate through a printing process, and attaching the first substrate and the second substrate to each other, wherein the first substrate and the second substrate are separated from each other by the spacers. The first substrate includes a plurality of light-emitting elements, the second substrate includes a plurality of optical filter elements, and the light-emitting elements respectively overlap the optical filter elements.

According to some embodiments, the present disclosure discloses a display device. The display device includes a first substrate, a second substrate, an adhesive material, and a plurality of spacers. The first substrate includes a plurality of light-emitting elements, the second substrate includes a plurality of optical filter elements, and the optical filter elements respectively overlap the light-emitting elements. The adhesive material is disposed between the first substrate and the second substrate, and the spacers are respectively disposed on multiple light-emitting elements, such that the first substrate and the second substrate are separated by the spacers.

According to some embodiments, the present disclosure discloses a display device. The display device includes a first substrate, a second substrate, a plurality of spacers, and an adhesive material. The first substrate includes a plurality of light-emitting elements, the second substrate includes a plurality of optical filter elements, and the optical filter elements respectively overlap the light-emitting elements. The spacers are disposed between the first substrate and the second substrate, and the adhesive material is disposed between the first substrate and the second substrate. One of the spacers has a maximum height and a maximum width, and at least one of the maximum height and the maximum width ranges from 0.1 μm to 300 μm.

DETAILED DESCRIPTION

The contents of the present disclosure will be described in detail with reference to specific embodiments and drawings. It is noted that, for purposes of illustrative clarity and being easily understood by the readers, the following drawings may be simplified schematic diagrams, and elements therein may not be drawn to scale. The numbers and sizes of the elements in the drawings are just illustrative and are not intended to limit the scope of the present disclosure.

Certain terms are used throughout the specification and following claims to refer to particular elements. Those skilled in the art should understand that electronic equipment manufacturers may refer to an element by different names. This document does not intend to distinguish between elements that differ in name but not function. In the following description and claims, the terms “include”, “comprise” and “have” are used in an open-ended fashion, and thus should be interpreted to mean “include, but not limited to . . . ”.

Ordinal numbers such as “first” and “second” in the specification and claim are used to modify the elements in the claim. It does not mean that the element has any previous ordinal numbers, nor does it mean the order of a certain element and another element, or the order in manufacturing method. The ordinal number is just used to make a claimed element with a certain name be clearly distinguishable from another claimed element with the same name. Therefore, a first element mentioned in the specification may be referred to as a second element in the claim.

Spatially relative terms, such as “above”, “on”, “left”, “right”, “front”, “behind” and the like, used in the following embodiments just refer to the directions in the drawings and are not intended to limit the present disclosure. It should be understood that the elements in the drawings may be disposed in any kind of formation known by one skilled in the related art to describe the elements in a certain way. In the specification, when one element overlaps the other element, it should be understood that the element may partially or completely overlap another.

In addition, when an element or layer is described as being on or above another element or layer, it should be understood that the element or layer is directly on the another element or layer, and alternatively, another element or layer may be between the element or layer and the another element or layer (indirectly). On the contrary, when the element or layer is described as being directly on the another element or layer, it should be understood that there is no intervening element or layer between them.

When an element is electrically connected or coupled to another element, it may include the case that there may be other elements between the element and the another element to electrically connect them or the case that the element and the another element are directly electrically connected without another element. When the element is directly electrically connected or directly coupled to the another element, it means that there is no other element between the element and the another element, and the element is directly electrically connected to the another element.

In the specification, the terms “approximately”, “about”, “substantially”, “roughly”, and “same” generally mean within 10%, 5%, 3%, 2%, 1%, or 0.5% of the reported numerical value or range. The quantity disclosed herein is an approximate quantity, that is, without a specific description of “approximately”, “about”, “substantially”, “roughly”, and “same”, the quantity may still include the meaning of “approximately”, “about”, “substantially”, “roughly”, and “same”.

It should be understood that according to the following embodiments, technical features in different embodiments may be replaced, recombined, or mixed to constitute other embodiments without departing from the spirit of the present disclosure. The technical features of various embodiments may be mixed arbitrarily and used in different embodiments without departing from the spirit of the present disclosure or conflicting.

In the present disclosure, the length, width, thickness, height or area, or the distance or spacing between elements may be measured by optical microscopy (OM), scanning electron microscope (SEM), a thin film thickness and surface profile gauge (α-step), an ellipsometer, or other suitable methods, but not limited thereto. Specifically, according to some embodiments, a scanning electron microscope can be used to obtain an image of the cross-sectional structure of the element to be measured, and the length, width, thickness, height or area of each element, or the distance or spacing between elements may be measured, but it is not limited thereto. In addition, any two values or directions used for comparison may have certain errors.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those skilled in the art to which the present disclosure belongs. It can be understood that these terms, such as those defined in commonly used dictionaries, should be interpreted as having the meaning consistent with the related art and the background or context of the present disclosure, and should not be interpreted in an ideal or overly formal way, unless specifically defined in the embodiments of the present disclosure.

In the present disclosure, the display device may optionally include light sensing, image sensing, touch, antenna, other suitable functions or a combination of the above functions, but it is not limited thereto. The display device may be a bendable, flexible or stretchable display device. In some embodiments, the display device may include a tiled device, but it is not limited thereto. The display device may include a light-emitting diode (LED), a quantum dot (QD) material, a fluorescent material, a phosphor material, other suitable materials or a combination of any two of the above, but it is not limited thereto. The light-emitting diode may include, for example, an organic light-emitting diode (OLED), a micro-LED, a mini-LED or a quantum dot light-emitting diode (QLED or QDLED), but it is not limited thereto. In addition, the display device may be, for example, a color display device, a monochrome display device or a grayscale display device. The display device may be, for example, in a shape of rectangular, circular, polygonal, a shape with curved edges, a curved surface, or other suitable shapes. The display device may optionally have a peripheral system such as a drive system, a control system, a light source system, a shelf system, etc.

Please refer toFIG.1, which is a schematic cross-sectional view of a display device according to a first embodiment of the present disclosure. In order to clearly show main features of the present disclosure, the drawings in the specification show cross-sectional views of portions of the display devices, but not limited thereto. As shown inFIG.1, the display device1may include a first substrate12, a second substrate14, an adhesive material16and a plurality of spacers18. The first substrate12may include a plurality of light-emitting elements20, the second substrate14may include a plurality of optical filter elements22, and the optical filter elements22may respectively overlap the light-emitting elements20along a top view direction TD. The adhesive material16and the spacers18may be disposed between the first substrate12and the second substrate14, such that the first substrate12and the second substrate14may be separated from each other by the spacers18. Through the disposition of the spacers18, a distance G (i.e., cell gap) between the first substrate12and the second substrate14may be uniformized, thereby reducing the unevenness of image brightness (mura), or improving the display quality.

In the embodiment ofFIG.1, the first substrate12may further include a circuit substrate24, and the light-emitting elements20may be disposed on the circuit substrate24, wherein the circuit substrate24may be used to control switches of the light-emitting elements20and the brightness of the light-emitting elements20, such that the display device1displays images. Although not shown inFIG.1, the circuit substrate24may include, for example, a substrate and a circuit layer. The substrate may include, for example, a flexible substrate or an inflexible substrate. The material of the substrate may include, for example, glass, ceramic, quartz, sapphire, acrylic, polyimide (PI), polyethylene terephthalate (PET), polycarbonate (PC), other suitable materials or a combination of the above, but not limited thereto. The circuit layer may include, for example, a plurality of pixel circuits and a plurality of signal lines. For example, one of the pixel circuits may include a 2T1C type pixel circuit (including two thin film transistors and one capacitor), a 7T2C type pixel circuit (including seven thin film transistors and two capacitors), a 7T3C type pixel circuit (including seven thin film transistors and three capacitors), a 3T1C type pixel circuit (including three thin film transistors and one capacitor), a 3T2C type pixel circuit (including three thin film transistors and two capacitors), but it is not limited thereto. The signal line may include, for example, a data line, a scan line and a power line, but not limited thereto. In some embodiments, the circuit layer may further include a circuit, such as a scan driver and a data driver, for controlling the display device1, but not limited thereto.

As shown inFIG.1, the light-emitting elements20may include a light-emitting element20a, a light-emitting element20b, and a light-emitting element20cfor respectively generating light L1, light L2, and light L3, and the optical filter elements22may include an optical filter element22a, an optical filter element22b, and an optical filter element22crespectively overlapping the light-emitting element20a, the light-emitting element20b, and the light-emitting element20c. In the embodiment ofFIG.1, the light-emitting element20a, the light-emitting element20band the light-emitting element20cmay be, for example, the same as each other, and the light L1, the light L2and the light L3may have the same color, such as blue light, light with a wavelength smaller than blue light, white light or other suitable colors, but it is not limited thereto. In some embodiments, at least two of the light L1, the light L2and the light L3may have the same color. In some embodiments, the light L1, the light L2and the light L3may have different colors from each other, but not limited thereto. The number of the light-emitting element20a, the number of the light-emitting element20b, the number of the light-emitting element20c, the number of the optical filter element22a, the number of the optical filter element22band the number of the optical filter element22care not limited to be one as shown inFIG.1and may be more than one.

As shown inFIG.1, one of the light-emitting elements20may include, for example, a P-type semiconductor layer202, an N-type semiconductor layer204, and a light-emitting layer206disposed between the P-type semiconductor layer202and the N-type semiconductor layer204. The light-emitting layer206may include, for example, a multi-quantum well (MQW) layer or other suitable layers. The light-emitting element20may further include, for example, a connection terminal P1and a connection terminal P2, wherein the connection terminal P1is disposed on a surface of the P-type semiconductor layer202facing the circuit substrate24, and the connection terminal P2is disposed on a surface of the N-type semiconductor layer204facing the circuit substrate24. The connection terminal P1and the connection terminal P2of the light-emitting element20may be bonded and electrically connected to the circuit substrate24, for example, by a flip-chip method. The connection terminal P1and the connection terminal P2may include, for example, pads, bumps and/or other suitable connection structures. In the embodiment ofFIG.1, the light-emitting layer206is disposed between the P-type semiconductor layer202and the N-type semiconductor layer204, and the P-type semiconductor layer202is disposed between the light-emitting layer206and the circuit substrate24. In this case, an area of the N-type semiconductor layer204may be greater than that of the P-type semiconductor layer202when viewed along the top view direction TD of the display device1. In some embodiments, positions of the P-type semiconductor layer202and the N-type semiconductor layer204may be interchangeable, that is, the light-emitting layer206may be disposed between the P-type semiconductor layer202and the N-type semiconductor layer204, and the N-type semiconductor layer204is disposed between the light-emitting layer206and the circuit substrate24. In such case, the area of the P-type semiconductor layer202may be greater than that of the N-type semiconductor layer204. The top view direction TD of the display device1may be, for example, a direction perpendicular to the display surface1S of the display device1, but not limited thereto.

In the embodiment ofFIG.1, the first substrate12may optionally further include a light-shielding layer26disposed on the circuit substrate24. The light-shielding layer26may include a plurality of openings OP1for accommodating the light-emitting elements20. For example, the light-shielding layer26may be used as a pixel definition layer, such that a region of one of the openings OP1may be used to define one pixel or sub-pixel of the display device1when viewed along the top view direction TD, but not limited thereto. The light-shielding layer26may include, for example, a light-shielding material, wherein the light-shielding material may include, for example, a photoresist material, an ink material, a pigment, a dye or other suitable materials. In some embodiments, a height of an upper surface26S of the light-shielding layer26may be lower than or higher than a height of an upper surface20S of one of the light-emitting elements20facing the second substrate14. The “height” mentioned herein may refer to a distance calculated based on the same horizontal plane. For example, the height of the upper surface26S of the light-shielding layer26may be a distance between the upper surface26S and an upper surface24S of the circuit substrate24, and the height of the upper surface20S of the light-emitting element20may be a distance between the upper surface20S of the N-type semiconductor layer204and the upper surface24S of the circuit substrate24.

As shown inFIG.1, the second substrate14may further include a transparent substrate28and a light-shielding layer30. The transparent substrate28may include, for example, a flexible substrate or an inflexible substrate. The material of the transparent substrate28may include, for example, glass, ceramic, quartz, sapphire, acrylic, polyimide, polyethylene terephthalate, polycarbonate, other suitable materials or a combination of the above, but not limited thereto. The light-shielding layer30may be disposed on a surface of the transparent substrate28facing the first substrate12and may have an opening OP2, an opening OP3and an opening OP4for accommodating the optical filter elements22. The number of opening OP2, the number of opening OP3, and the number of opening OP4are not limited to be one as shown inFIG.1and may be more than one. The light-shielding layer30may include, for example, a light-shielding material, wherein the light-shielding material may include, for example, a photoresist material, an ink material, a pigment, a dye or other suitable materials. The optical filter element22a, the optical filter element22b, and the optical filter element22cmay be respectively disposed in the opening OP2, the opening OP3, and the opening OP4. One of the optical filter elements22may include, for example, a color filter or other suitable filter elements, but not limited thereto. For example, the optical filter element22may include a photoresist material, an ink material, a pigment, a dye or other suitable materials.

In the embodiment ofFIG.1, a color of light L2generated by the light-emitting element20bmay be used as a color of a pixel or a sub-pixel, and the second substrate14may further include a light-shielding layer32, color conversion layers34, and a transparent filling layer36. The light-shielding layer32may be, for example, disposed under the light-shielding layer30and may have an opening OP5, an opening OP6and an opening OP7, which respectively overlap the opening OP2, the opening OP3and the opening OP4when viewed along the top view direction TD. The light-shielding layer32may include a light-shielding material. The color conversion layers34may respectively overlap the corresponding light-emitting elements20in the top view direction TD for converting the light generated by the corresponding light-emitting elements20into light with different colors. In the embodiment ofFIG.1, the color conversion layers34may include, for example, a color conversion layer34aand a color conversion layer34b, wherein the color conversion layer34amay absorb the light L1and generate light L4with a color different from the light L1, and the color conversion layer34bmay absorb the light L3and generate light L5with a color different from the light L3. The transparent layer36does not absorb the light L2and allows the light L2to pass through.

Specifically, as shown inFIG.1, the color conversion layer34aand the color conversion layer34bmay be respectively disposed in the opening OP5and the opening OP7, and the transparent filling layer36may be disposed in the opening OP6, such that the color conversion layer34a, the transparent filling layer36and the color conversion layer34bmay respectively overlap the optical filter element22a, the optical filter element22band the optical filter element22calong the top view direction TD. In this case, the light L4generated by the color conversion layer34aand the light L5generated by the color conversion layer34bmay respectively be directed to the optical filter element22aand the optical filter element22c, and the light L2passing through the transparent filling layer36may be directed to the optical filter element22b. The optical filter element22a, the optical filter element22band the optical filter element22cmay be, for example, color filters with different colors. For example, the color of the optical filter element22amay be the same as or close to the color of the light L4, the color of the optical filter element22cmay be the same as or close to the color of the light L5, and the color of the optical filter element22bmay be the same as or close to the color of the light L2. Therefore, the light L4, the light L5and the light L2may respectively pass through the optical filter element22a, the optical filter element22cand the optical filter element22band then be respectively emitted from the display surface1S of the display device1, so as to be the lights generated by different sub-pixels of the same pixel of the display device1(or the lights generated by different pixels). For example, wavelengths corresponding to the maximum light intensity peaks of the light L1and the light L3may be respectively less than the wavelengths corresponding to the maximum light intensity peaks of the light L4and the light L5. The light L4, the light L2and the light L5may be, for example, mixed to be a white light. For example, the light L4, the light L2and the light L5may be a red light, a blue light and a green light respectively, and the optical filter element22a, the optical filter element22band the optical filter element22cmay be a red filter, a blue filter and a green filter respectively, but not limited thereto. In some embodiments, the colors of the optical filter element22a, the optical filter element22b, and the optical filter element22cmay be adjusted according to the colors of the light L4, the light L2, and the light L5respectively, but not limited thereto. In some embodiments, the color conversion layer34aand the color conversion layer34bmay include, for example, a fluorescent material, a phosphorescent material, quantum dot particles, or other light conversion materials that is able to convert the color of light.

It is worth noting that, since the optical filter element22amay block (absorb or reflect) at least a portion of light with a color different from that of the light L4, the optical filter element22bmay block (absorb or reflect) at least a portion of light with a color different from that of the light L2, and the optical filter element22cmay block (absorb or reflect) at least a portion of light with a color different from that of the light L5, the colors of the light L4, the light L2and the light L5passing through the optical filter element22a, the optical filter element22band the optical filter element22cand then being emitted from the display surface1S is purified to meet requirements. In some embodiments, an arrangement order of the color conversion layer34a, the transparent filling layer36and the color conversion layer34bis not limited asFIG.1, but may be other arrangements. The positions of optical filter element22a, optical filter element22band optical filter element22cmay be designed according to the positions of color conversion layer34a, transparent filling layer36and color conversion layer34b. In some embodiments, the second substrate14may optionally include, for example, scattering particles (not shown in figures) disposed in the transparent filling layer36. In some embodiments, the transparent filling layer36may be replaced with a color conversion layer, but not limited thereto. For example, when the color of the light L2is not the color of one of the sub-pixels in the display device1, the color conversion layer34instead of the transparent filling layer may convert the color of the light L2into the same color as the sub-pixel. In some embodiments, the color conversion layer34may be replaced with the transparent filling layer36, but it is not limited thereto. For example, when the color of light L1or light L3is the same as the color of one of the sub-pixels in the display device1, the transparent filling layer36instead of the color conversion layer34may allow the light L1or light L3to pass through, which may be regarded as the light of the sub-pixel.

In some embodiments, as shown inFIG.1, the second substrate12may optionally include an encapsulation layer38disposed under the light-shielding layer32, the color conversion layer34and the transparent filling layer36to reduce or avoid damage of the color conversion layer34caused by moisture or oxygen. The material of the encapsulation layer38may include, for example, a stack of an inorganic material layer, an organic material layer and an inorganic material layer, a single inorganic material layer, a stack of multiple inorganic material layers or other suitable layers. For example, the inorganic material layer may include silicon nitride, silicon oxide, silicon oxynitride, aluminum oxide or other suitable protective materials, or any combination of the above inorganic materials, but it is not limited thereto. The organic material layer may include resin, but it is not limited thereto.

As shown inFIG.1, the spacers18may be disposed between the first substrate12and the second substrate14, and an upper surface S1and a lower surface S2of one of the spacers18may directly contact the second substrate14and the first substrate12, respectively. Therefore, the spacers18are used to support a space between the first substrate12and the second substrate14, such that the distance G between the first substrate12and the second substrate14may be uniformized. The distance G may be, for example, a distance between a lower surface of the second substrate14facing the first substrate12and an upper surface of the first substrate12. In the embodiment ofFIG.1, the lower surface of the second substrate14may be, for example, a lower surface38S of the encapsulation layer38facing the first substrate12, and the distance G may be, for example, a distance between the lower surface38S of the encapsulation layer38facing the first substrate12and the upper surface20S of the light-emitting element20facing the second substrate14. The distance G may be, for example, greater than 0 μm and less than 5 μm (0 μm<distance G<5 μm). For example, a difference between a maximum distance and a minimum distance between the first substrate12and the second substrate14may be less than or equal to 10% of the maximum distance or 10% of the minimum distance, such that the display device1has a uniform distance G.

In the embodiment ofFIG.1, the spacers18may be respectively disposed on a plurality of the light-emitting elements20and may not overlap the light-emitting layers206. For example, one of the spacers18may be disposed on a portion of the N-type semiconductor layer204that does not overlap the light-emitting layer206along the top view direction TD, so as to reduce the influence of the spacer18on the brightness of the corresponding light-emitting element20. In some embodiments, when the positions of the N-type semiconductor layer204and the P-type semiconductor layer202exchange, such that the N-type semiconductor layer204is disposed between the light-emitting layer206and the circuit substrate24, and the P-type semiconductor layer202is disposed on the light-emitting layer206, one of the spacers18may be disposed on a portion of the P-type semiconductor layer202that does not overlap the light-emitting layer206along the top view direction TD.

In some embodiments, the spacer18may be, for example, in a dome shape. For example, the upper surface S1of the spacer18is a convex curved surface, and an edge of the upper surface S1may be connected with the lower surface S2. In some embodiments, the spacer18may have a maximum height H and a maximum width W, and a ratio of the maximum width W to the maximum height H may range from, for example, about 0.3 to 8(0.3≤W/H≤8). For example, the maximum height H may range from 0.1 μm to 300 μm or from 0.1 μm to 30 μm (0.1 μm≤maximum height H≤300 μm or 0.1 μm≤maximum height H≤30 μm), and/or the maximum width W may range from 0.1 μm to 300 μm or from 0.1 μm to 7 μm (0.1 μm≤maximum width W≤300 μm or 0.1 μm≤maximum width W≤7 μm), but not limited thereto. In some embodiments, a visible light transmittance of the spacer18may be, for example, greater than or equal to 90% to improve the brightness of the light of the light-emitting element20emitted from the display surface1S of the display device1. In some embodiments, a haze of the spacer18may be, for example, less than or equal to 1%. In the present disclosure, the haze is defined as, for example, an intensity of a transmission light passing through the spacer18and having an outgoing direction that deviates from an incident direction of an incident light into the spacer18by 2.5 degrees or more divided by a total intensity of all transmission light passing through the spacer18(i.e., (luminous flux of the transmission light deviating from the incident direction by 2.5 degrees or more)/(total luminous flux of all the transmission light)), but not limited thereto. In some embodiments, the compressible range of the spacer18may be, for example, greater than 0.15 μm or greater than 3 μm. The compressible range of the spacer18may be determined, for example, according to the material of the spacer18and the distance G of the display device1.

As shown inFIG.1, the display device1may further include a sealing layer40to reduce leakage of the adhesive material16before the adhesive material16is cured. The sealing layer40and the adhesive material16may be used for bonding the first substrate12to the second substrate14. The sealing layer40may surround the adhesive material16to seal the adhesive material16between the first substrate12and the second substrate14. In the embodiment ofFIG.1, the adhesive material16disposed between the first substrate12and the second substrate14may be disposed in the opening OP1of the light-shielding layer26, but not limited thereto. The sealing layer40may include, for example, an encapsulant material or other suitable materials.

It should be noted that, in some embodiments, because a refractive index of the N-type semiconductor layer204or the P-type semiconductor layer202is greater than that of the adhesive material16, the design that a refractive index of the spacer18is greater than that of the adhesive material16may reduce a total reflection of the light emitted from the light-emitting element20that is generated between the light-emitting element20and the adhesive material16, thereby improving light extraction efficiency of the light-emitting element20. For example, the refractive index of the spacer18may be between the refractive index of the N-type semiconductor layer204or the P-type semiconductor layer202and the refractive index of the adhesive material16. The N-type semiconductor layer204or the P-type semiconductor layer202may include, for example, gallium nitride or other suitable semiconductor materials. The spacer18may include, for example, a photosensitive resin, an ink or other suitable materials, and the photosensitive resin may be cured by ultraviolet light or other suitable means. The adhesive material16may include, for example, optical clear resin (OCR) or other suitable materials.

Please refer toFIG.2which is a flowchart of a manufacturing method of a display device according to some embodiments of the present disclosure. As shown inFIG.2, the manufacturing method of the display device may include, for example, step S12to step S18, and is described in detail below with references ofFIG.1andFIG.2. As shown inFIG.1andFIG.2, in step S12, a first substrate12is provided. For example, step S12of providing the first substrate12may include providing the circuit substrate24, forming the light-shielding layer26on the circuit substrate24, and then bonding the light-emitting elements20on the circuit substrate24, but not limited thereto. After step S12, step S14may be performed to form a plurality of spacers18on the first substrate12. The spacers18may be formed on the light-emitting elements20, for example, by photolithography and etching processes, a printing process or other suitable processes, wherein the printing process may include an inkjet printing process, but not limited thereto. The inkjet printing process may accurately control sizes and positions of the spacers18formed on the first substrate12. When the spacers18are formed through the printing process, the spacers18may be cured after the printing process. In some embodiments, when the spacers18are formed by the inkjet printing process, the spacers18may include, for example, epoxy, acrylic, other suitable materials, or a combination of at least two of the above, but not limited thereto. When the spacers18include epoxy, the spacers18may be cured, for example, by heating. When the spacers18include an acrylic material, the spacers18may be cured, for example, by lighting (such as ultraviolet light). Alternatively, the spacers18may be cured by heating and lighting, but not limited thereto.

As shown inFIG.1andFIG.2, in step S16, the second substrate14is provided. The light-shielding layer30, the light-shielding layer32, the optical filter element22, the color conversion layer34, and the encapsulation layer38may be respectively formed, for example, by exposure and development processes, the inkjet printing process, or other suitable processes, and required processes may be performed according to different materials, so they are not described in detail here. Since step S12and step S14do not affect the progress of step S16, step S12and step S14may be performed before or after step S16, or at least one of step S12and step S14may be performed simultaneously with step S16, but not limited thereto. After step S14of forming the spacer18and step S16of providing the second substrate14, step S18may be carried out to attach the first substrate12formed with the spacers18and the second substrate14to each other, wherein the first substrate12and the second substrate14are separated from each other by the spacers18. For example, step S18of attaching the first substrate12and the second substrate14to each other may include disposing the sealing layer40on the first substrate12, such that the sealing layer40surrounds all the light-emitting elements20when viewed along the top view direction TD, disposing the adhesive material16in a region surrounded by the sealing layer40, and then attaching the second substrate14and the first substrate12to each other through the sealing layer40and the adhesive material16. Afterwards, the sealing layer40and the adhesive material16are cured by a curing process, such that the display device1is formed. It should be noted that in step S18, since the spacers18between the first substrate12and the second substrate14have been cured before the adhesive material16is cured, the spacers18are able to support the space between the first substrate12and the second substrate14, and thus the distance G between the first substrate12and the second substrate14may be uniformized.

The display device and the manufacturing method thereof are not limited to the above embodiments, and may have different embodiments. To simplify the explanation, the reference numbers in different embodiments are named the same as those of the first embodiment to label the same elements. In order to easily compare the differences between the first embodiment and other embodiments, the differences between different embodiments are highlighted below, and the same portion is not described in detail.

FIG.3is a schematic cross-sectional view of a display device according to a second embodiment of the present disclosure. As shown inFIG.3, one of differences between the display device2of the present embodiment and the display device1shown inFIG.1is that the light L1generated by the light-emitting element20a, the light L2generated by the light-emitting element20band the light L3generated by the light-emitting element20cof the present embodiment may have different colors. For example, the light L1, the light L2and the light L3may be mixed into white light, and they are, for example, red light, blue light, and green light, respectively, but not limited thereto. In this case, the second substrate14of the display device2may optionally not include the light-shielding layer32, the color conversion layer34and the transparent filling layer36shown inFIG.1. The light L1, the light L2and the light L3may respectively pass through the optical filter element22a, the optical filter element22band the optical filter element22c. It is noted that since the optical filter element22a, the filter22band the filter22chave different colors, they have different transmittances for light of different wavelength ranges. Accordingly, the optical filter element22a, the optical filter element22band the optical filter element22cmay have an effect of anti-reflection, and thus interference of ambient light on the image displayed by the display device2may be reduced. In some embodiments, the display device2may optionally not include the encapsulation layer38. In this case, the lower surface of the second substrate14may be, for example, a lower surface22S of the optical filter element22facing the first substrate12, and the distance G between the first substrate12and the second substrate14may be, for example, a distance between the lower surface22S of the optical filter element22and the upper surface20S of the light-emitting element20. The distance G may be, for example, greater than 0 μm and less than 5 μm (0 μm<spacing G<5 μm). Other portions of the display device2shown inFIG.3may be, for example, the same as those of the display device1shown inFIG.1, so the details are not repeated. The manufacturing method of the display device2shown inFIG.3may be similar to that shown inFIG.2, and differences between them is that the second substrate14ofFIG.3does not include the light-shielding layer32, the color conversion layer34and the transparent filling layer36. Other steps are the same as the manufacturing method shown inFIG.1andFIG.2.

FIG.4is a schematic cross-sectional view of a display device according to the third embodiment of the present disclosure. As shown inFIG.4, one of the differences between the display device3of the present embodiment and the display device1shown inFIG.1is that the first substrate12of the present embodiment does not include the light-shielding layer26. It should be noted that when the resolution of the display device3reaches a certain level, the light-shielding layer26is not easily disposed between the light-emitting elements20. Therefore, the display device3may not include the light-shielding layer26. In this case, the spacers18may be disposed on the light-emitting elements20. In the embodiment ofFIG.4, the distance G between the first substrate12and the second substrate14may be, for example, a distance between the lower surface38S of the encapsulation layer38facing the first substrate12and the upper surface20S of one of the light-emitting elements20. The distance G may be, for example, greater than 0 μm and less than 5 μm(0 μm<distance G<5 μm). Other portions of the display device3shown inFIG.4may be, for example, the same as those of the display device1shown inFIG.1, so the details are not repeated. The manufacturing method of the display device3shown inFIG.4may be similar to that shown inFIG.2, and a difference between them is that the first substrate12inFIG.4does not include the light-shielding layer26. Other steps may be the same as those ofFIG.1andFIG.2. In some embodiments, the light-emitting elements20in the display device3ofFIG.4may adopt the light-emitting elements20ofFIG.3, so the light-shielding layer32, the color conversion layer34and the transparent filling layer36shown inFIG.1may not be included. In some embodiments, the display device3may optionally not include the encapsulation layer38.

FIG.5is a schematic cross-sectional view of a display device according to a fourth embodiment of the present disclosure. As shown inFIG.5, one of the differences between the display device4of the present embodiment and the display device1shown inFIG.1is that one of the spacers18disposed on one of the light-emitting elements20in the present embodiment may at least partially overlap the light-emitting layer206when viewed along the top view direction TD. In the embodiment ofFIG.5, the spacer18may cover the upper surface20S of the light-emitting element20(e.g., the upper surface of the N-type semiconductor layer204). It is noted that since the refractive index of the spacer18may be greater than that of the adhesive material16(e.g., may be between the refractive index of the N-type semiconductor layer204or the P-type semiconductor layer202and the refractive index of the adhesive material), the total reflection of the light emitted from the light-emitting element20that is generated between the light-emitting element20and the adhesive material16may be reduced, thereby improving the light extraction efficiency of the light-emitting element20. In addition, the spacer18may be, for example, in a dome shape, such that the spacer18has an advantage of concentrating the light generated by the light-emitting element20upwardly, thereby reducing light mixing of adjacent light with different colors. In some embodiments, the visible light transmittance of the spacer18may be greater than or equal to 90%, and/or the haze of the spacer18may be less than or equal to 1%, which may reduce the influence of the spacer18on the light extraction efficiency (or external quantum efficiency, EQE)) of the light emitting element20.

Other portions of the display device4shown inFIG.5may adopt, for example, the corresponding portions of the display device1shown inFIG.1, and the manufacturing method of the display device4shown inFIG.5may be similar to or the same as that ofFIG.2, so the details are not repeated. In some embodiments, the light-emitting elements20in the display device4ofFIG.5may adopt the light-emitting elements20ofFIG.3, so the display device4ofFIG.5may not include the light-shielding layer32, the color conversion layer34and the transparent filling layer36shown inFIG.1. In some embodiments, the display device4may optionally not include the encapsulation layer38.

FIG.6is a schematic cross-sectional view of a display device according to a fifth embodiment of the present disclosure. As shown inFIG.6, one of the differences between the display device5of the present embodiment and the display device4inFIG.5is that the first substrate12of the present embodiment may not include the light-shielding layer26, which is similar to the display device3shown inFIG.4. In the embodiment ofFIG.6, the distance G between the first substrate12and the second substrate14may be, for example, the distance between the lower surface38S of the encapsulation layer38facing the first substrate12and the upper surface20S of one of the light-emitting elements20. Other portions of the display device5shown inFIG.6may adopt, for example, those corresponding portions of the display device1shown inFIG.1, so the details are not repeated. The manufacturing method of the display device5shown inFIG.6may be similar to that ofFIG.2, the difference between them is that the first substrate12inFIG.6does not include the light-shielding layer26, and other steps may be the same as those shown inFIG.1andFIG.2. In some embodiments, the light-emitting elements20in the display device5ofFIG.6may adopt the light-emitting elements20ofFIG.3, so the display device5ofFIG.6may not include the light-shielding layer32, the color conversion layer34and the transparent filling layer36shown inFIG.1. In some embodiments, the display device5may optionally not include the encapsulation layer38.

FIG.7is a schematic cross-sectional view of a display device according to a sixth embodiment of the present disclosure. As shown inFIG.7, one of the differences between the display device6of the present embodiment and the display device1shown inFIG.1is that the spacers18of the present embodiment are in granular shapes. In other words, the spacers18may be disposed on the first substrate12, for example, by spreading. In some embodiments, the granular spacers18may include, for example, a glass-based material or a resin-based material, but not limited thereto. In the embodiment ofFIG.7, the spacers18may be disposed on the light-shielding layer26. In some embodiments, two of the spacers18may be respectively disposed on the light-shielding layer26and the light-emitting element20, or one of the spacers18may be disposed on both the light-shielding layer26and one of the light-emitting elements20, but not limited thereto. In this case, the visible light transmittance of one of the spacers18may be, for example, greater than or equal to 90%, and/or the haze of the spacer18may be less than or equal to 1%, which reduces the influence of the spacers18on the light extraction efficiency of the light-emitting elements20. In some embodiments, a distribution density range of the spacers18may be, for example, about 0.01% to 0.15%(0.01%≤distribution density≤0.15%) and may be, for example, determined according to requirements of product design. The distribution density of the present disclosure may be a total area of all the spacers18viewed along the top view direction TD divided by an area of a display region of the display device6(that is, the total area of all the spacers18/the area of the display region). The display region of the display device6may be, for example, determined by a distribution range of the light-emitting elements20. In some embodiments, particle sizes of the spacers18may be, for example, 1 μm to 600 μm or 1 μm to 5 μm(1 μm≤particle size≤600 μm or 1 μm particle size≤5 μm) and may be determined, for example, according to optical requirements. The light-emitting elements20ofFIG.7may adopt, for example, the same as or similar to the light emitting elements20shown inFIG.1or other types of light-emitting elements. Other portions of the display device6shown inFIG.7may adopt, for example, those corresponding portions of the display device1shown inFIG.1, so the details are not repeated. The manufacturing method of the display device6ofFIG.7may be similar to that ofFIG.2, the differences between them are that the spacers18ofFIG.7are disposed on the first substrate12or the second substrate14by spreading, and the spacers18are cured before attaching the first substrate12and the second substrate14to each other, while other steps may be the same as the manufacturing methods shown inFIG.1andFIG.2, so the details are not repeated. In some embodiments, the light-emitting elements20in the display device6ofFIG.7may adopt the light-emitting elements20ofFIG.3, so the display device6ofFIG.7may not include the light-shielding layer32, the color conversion layer34and the transparent filling layer36shown inFIG.1. In some embodiments, the display device6may optionally not include the encapsulation layer38.

FIG.8is a schematic cross-sectional view of a display device according to a seventh embodiment of the present disclosure. As shown inFIG.8, one of the differences between the display device7of the present embodiment and the display device1shown inFIG.1is that one of the spacers18of the present embodiment may be formed on the light-shielding layer26of the first substrate12. For example, the spacer18may be formed on the light-shielding layer26by photolithography and etching processes, a printing process or other suitable processes. The spacer18may include, for example, a photosensitive resin, an ink or other suitable materials. Since the spacer18is disposed on the light-shielding layer26instead of the light-emitting elements20, the transmittance of the spacer18does not require to be limited in a specific range. In some embodiments, the spacer18may include, for example, a light-shielding material to reduce light mixing of adjacent light-emitting elements20. In some embodiments, a width of the spacer18in a horizontal direction HD perpendicular to the top view direction TD may gradually decrease as a distance between the width of the spacer18and the upper surface26S of the light-shielding layer26gradually increases. In other words, the width of a bottom of the spacer18adjacent to the light-shielding layer26is greater than the width of a top of the spacer18adjacent to the second substrate14.

The light-emitting elements20ofFIG.8may be, for example, the same as or similar to the light-emitting elements20shown inFIG.1or other types of light-emitting elements. Other portions of the display device7shown inFIG.8may adopt, for example, corresponding portions of the display device1shown inFIG.1, so the details are not repeated. The manufacturing method of the display device7ofFIG.8may be similar to that ofFIG.2, and the difference between them is that the spacers18ofFIG.8are formed on the light-shielding layer26, while other steps may be the same as those shown inFIG.1andFIG.2. The details are not repeated. In some embodiments, the light-emitting elements20in the display device7ofFIG.8may adopt the light-emitting elements20ofFIG.3, so the display device7ofFIG.8may not include the light-shielding layer32, the color conversion layer34and the transparent filling layer36shown inFIG.1. In some embodiments, the display device7may optionally not include the encapsulation layer38.

FIG.9is a schematic cross-sectional view of a display device according to an eighth embodiment of the present disclosure. As shown inFIG.9, one of the differences between the display device8of the present embodiment and the display device7shown inFIG.8is that one of the spacers18of the present embodiment is formed on the light-shielding layer30of the second substrate14. For example, the spacer18may be formed on the encapsulation layer38by photolithography and etching processes, an inkjet printing process or other suitable processes. In the embodiment ofFIG.9, the spacer18may overlap the light-shielding layer30or the light-shielding layer32when viewed along the top view direction TD. In some embodiments, the spacer26may include, for example, a light-shielding material to reduce light mixing of adjacent light-emitting elements20. In some embodiments, the width of the spacer18in the horizontal direction HD may gradually decrease as the distance between the width of the spacer18and the lower surface of the encapsulation layer38gradually increases. In other words, the width of the bottom of the spacer18adjacent to the encapsulation layer38is greater than the width of the top of the spacer18adjacent to the first substrate12. The light-emitting elements20ofFIG.9may be, for example, the same as or similar to the light-emitting elements20shown inFIG.1or other types of light-emitting elements. Other portions of the display device8shown inFIG.9may adopt, for example, corresponding portions of the display device1shown inFIG.1, so the details are not repeated.

Please refer toFIG.10, which is a flowchart of a manufacturing method of a display device according to some embodiments of the present disclosure. As shown inFIG.10, the manufacturing method of the display device may include, for example, step S12, step S16, step S18and step S22. As shown inFIG.9andFIG.10, in step S12, the first substrate12is provided. In step S16, the second substrate14is provided. Since step S12and step S16may be similar to or the same as step S12and step S16inFIG.1andFIG.2, respectively, the details are not repeated. After step S16, step S22may be performed to form a plurality of spacers18on the second substrate14. The spacers18may be formed on the second substrate14, for example, by photolithography and etching processes, a printing process or other suitable processes, wherein the printing process may include, for example, inkjet printing. When the spacers18are formed through the printing process, the spacers18may be cured after the printing process. Since the material of the spacers18may be the same as or similar to that of the spacers18shown inFIG.1andFIG.2, the details are not repeated.

Since step S12does not affect the progress of step S16and step S22, step S12may be performed before or after step S16and step S22, or step S12may be performed simultaneously with at least one of step S16and step S22, but not limited thereto. After step S12of providing the first substrate12and step S22of forming the spacers18, step S18may be performed to attach the first substrate12and the second substrate14having the spacers18formed thereon, such that the first substrate12and the second substrate14may be separated from each other by the spacers18during attaching, thereby forming the display device8. Step S18may be similar to or the same as step S18inFIG.1andFIG.2, respectively, so the details are not repeated.

In some embodiments, the light-emitting elements20in the display device8ofFIG.9may adopt the light-emitting elements20ofFIG.3, so the display device8ofFIG.9may not include the light-shielding layer32, the color conversion layer34and the transparent filling layer36shown inFIG.1. In some embodiments, the display device8may optionally not include the encapsulation layer38. In this case, the spacers18may be formed on the light-shielding layer30.

In summary, in the display device and the manufacturing method thereof of the present disclosure, the spacers are disposed between the first substrate and the second substrate and separate the first substrate from the second substrate, such that the distance between the first substrate and the second substrate may be uniformized, thereby improving the display quality.