Patent Publication Number: US-2021175202-A1

Title: Light-emitting apparatus including sacrificial pattern

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional application of U.S. application Ser. No. 16/518,962, filed on Jul. 22, 2019, now pending, which claims the priority benefit of Taiwan application serial no. 108100342, filed on Jan. 4, 2019. The entirety of each of the above-mentioned patent applications is hereby incorporated by reference herein and made a part of this specification. 
    
    
     BACKGROUND 
     Field of the Disclosure 
     The present disclosure relates to an electronic apparatus and a manufacturing method thereof, and more particularly to a light-emitting apparatus and a manufacturing method thereof. 
     Description of Related Art 
     The transfer micro-device technique is applied in the process of new electronic apparatuses. In the case of the process of a light emitting apparatus, the process of the light emitting apparatus includes the following steps: providing a transfer stamp having a plurality of transfer blocks; providing a plurality of light-emitting diode elements to make the transfer block of the transfer stamp to contact the light-emitting diode element and further pick up the light-emitting diode element to be used; transferring the light-emitting diode element to an adhesive layer of a receiving substrate by using the transfer stamp; manufacturing an interconnection layer on the receiving substrate carrying the plurality of light-emitting diode elements such that the light-emitting diode elements are electrically connected to the pads of the receiving substrate. However, the plurality of light-emitting diode elements, the pads of the receiving substrate and the interconnection layer must be accurately aligned with each other so that the light-emitting diode elements can be electrically connected to the pads of the receiving substrate, which makes it difficult for the yield rate of light-emitting apparatus to be improved. 
     SUMMARY OF THE DISCLOSURE 
     The disclosure provides a light-emitting apparatus and a manufacturing method thereof, which have high yield rate. 
     A light-emitting apparatus of the present disclosure includes a substrate, a plurality of pads, a sacrificial pattern layer, a light-emitting diode element, and a plurality of connection patterns. The plurality of pads are disposed on the substrate. The sacrificial pattern layer is disposed on the substrate. The light-emitting diode element is disposed on the sacrificial pattern layer. The light-emitting diode element includes a first type semiconductor layer, a second type semiconductor layer with respect to the first type semiconductor layer, an active layer between the first type semiconductor layer and the second type semiconductor layer, and a plurality of electrodes respectively electrically connected to the first type semiconductor layer and the second type semiconductor layer. The plurality of connection patterns respectively disposed on at least one of the plurality of electrodes and the plurality of pads. The material of the plurality of connection patterns includes a hot fluidity conductive material, and the plurality of connection patterns cover sidewalls of the sacrificial pattern layer and are electrically connected to the at least one of the plurality of pads and the plurality of electrodes. 
     A manufacturing method of a light-emitting apparatus of the present disclosure includes the steps of: providing a substrate and a plurality of pads disposed on the substrate; forming a sacrificial material layer on the substrate to cover the plurality of pads; and disposing a light-emitting diode element on the sacrificial material layer, wherein the light-emitting diode element includes a first type semiconductor layer, a second type semiconductor layer, an active layer disposed between the first type semiconductor layer and the second type semiconductor layer, and a plurality of electrodes respectively electrically connected to the first type semiconductor layer and the second type semiconductor layer; forming a plurality of connection patterns disposed on at least one of the plurality of electrodes and the plurality of pads, and the material of the plurality of connection patterns includes a hot fluidity conductive material; patterning the sacrificial material layer to form a sacrificial pattern layer, and forming a plurality of gaps between the plurality of connection patterns and the plurality of pads or between the plurality of pads and the plurality of electrodes, wherein the sacrificial pattern layer exposes at least a portion of each of the plurality of pads; and performing a heating process to make the plurality of connection patterns to flow to be electrically connected to the at least one of the plurality of pads and the plurality of electrodes. 
     In order to make the aforementioned features and advantages of the disclosure more comprehensible, embodiments accompanying figures are described in detail below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  to  FIG. 1C  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a first embodiment of the present disclosure. 
         FIG. 2A  to  FIG. 2C  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a second embodiment of the present disclosure. 
         FIG. 3A  to  FIG. 3C  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a third embodiment of the present disclosure. 
         FIG. 4A  to  FIG. 4C  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a fourth embodiment of the present disclosure. 
         FIG. 5A  to  FIG. 5C  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a fifth embodiment of the present disclosure. 
         FIG. 6  is a schematic top view showing a light-emitting apparatus according to a fifth embodiment of the present disclosure. 
         FIG. 7A  to  FIG. 7F  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a sixth embodiment of the present disclosure. 
         FIG. 8A  to  FIG. 8F  are schematic top views showing a manufacturing process of a light-emitting apparatus according to a sixth embodiment of the present disclosure. 
         FIG. 9A  to  FIG. 9F  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a seventh embodiment of the present disclosure. 
         FIG. 10A  to  FIG. 10F  are schematic top views showing a manufacturing process of a light-emitting apparatus according to a seventh embodiment of the present disclosure. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     In the accompanying drawings, thicknesses of layers, films, panels, regions and so on are exaggerated for clarity. Throughout the specification, the same reference numerals in the accompanying drawings denote the same devices. It should be understood that when an element such as a layer, film, region or substrate is referred to as being “on another element” or “connected to another element,” it can be directly on or connected to the other element, or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” or “directly connected to” another element, there are no intervening elements present. As used herein, the term “connected” may refer to physically connected and/or electrically connected. Furthermore, “electrical connection” or “coupling” may be that other elements are present between two elements. 
     The term “about,” “similar,” or “substantially” as used herein is inclusive of the stated value and means within an acceptable range of deviation for the particular value as determined by people having ordinary skill in the art, considering the measurement in question and the error associated with measurement of the particular quantity (i.e., the limitations of the measurement system) or the limitations of the manufacturing system. For instance, “about” may mean within one or more standard deviations, or within, for example, ±30%, ±20%, ±10%, or ±5% of the stated value. Moreover, a relatively acceptable range of deviation or standard deviation may be chosen for the term “about,” “approximately,” or “substantially” as used herein based on optical properties, etching properties or other properties, instead of applying one standard deviation across all the properties. 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by persons of ordinary skill in the art. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. 
     Exemplary embodiments of the disclosure are described with reference of schematic cross-sectional views of the idealized embodiments. Therefore, a shape variation of the drawings as a result of a manufacturing technique and/or manufacturing tolerance, for example, is expected. Therefore, the embodiments of the disclosure should not be interpreted as being limited to specific shapes of the regions shown in the drawings but may include a shape deviation caused during manufacture, for example. For example, a flat area shown in the figures or described herein may practically have rough and/or non-linear characteristics. Moreover, an acute angle shown in the drawings can practically be rounded. Therefore, the shapes shown in the figures are substantially schematic, and the shapes therein are not intended to represent accurate shapes, and are not intended to serve as limitations of the claims. 
     Reference will now be made in detail to the exemplary embodiments. Examples of exemplary embodiments are described in the accompanying drawings. Wherever possible, the same reference symbols are used to denote the same or similar parts in the drawings and the description. 
       FIG. 1A  to  FIG. 1C  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a first embodiment of the present disclosure. 
     Referring to  FIG. 1A , first, an active device substrate A is provided. The active device substrate A includes a substrate  110  and a plurality of pads  130   a  and  130   b  disposed on the substrate  110 . In this embodiment, the material of the pads  130   a  and  130   b  is, for example, metal, but the disclosure is not limited thereto. In this embodiment, the active device substrate A further includes a driving circuit layer  120  electrically connected to the pads  130   a  and  130   b . For example, the driving circuit layer  120  may include a data line (not shown), a scan line (not shown), a power line (not shown), a common line (not shown), a first transistor (not shown) and a second transistor (not shown). The first transistor has a first end, a second end and a control end, and the second transistor also has a first end, a second end and a control end. The first end of the first transistor is electrically connected to the data line, the control end of the first transistor is electrically connected to the scan line, the second end of the first transistor is electrically connected to the control end of the second transistor, and the first end of the second transistor is electrically connected to the power line. The second end of the second transistor is electrically connected to one of the pads  130   a  and  130   b , and the other of the pads  130   a  and  130   b  is electrically connected to the common line. However, the present disclosure is not limited thereto, and in other embodiments, the driving circuit layer  120  may be of other forms. 
     Referring to  FIG. 1A , then, a sacrificial material layer  140  is formed on the substrate  110  to cover the plurality of pads  130   a  and  130   b . The sacrificial material layer  140  can also be referred to as a bonding layer. For example, in this embodiment, the material of the sacrificial material layer  140  may be a photoresist, a heat curing adhesive or other suitable material. 
     Referring to  FIG. 1A , next, a light-emitting diode element  150  is disposed on the sacrificial material layer  140 . The light-emitting diode element  150  is bonded to the active device substrate A through the sacrificial material layer  140 . The light-emitting diode element  150  includes a first type semiconductor layer  152   a , a second type semiconductor layer  152   b , an active layer  154  disposed between the first type semiconductor layer  152   a  and the second type semiconductor layer  152   b , and a plurality of electrodes  156   a  and  156   b  electrically connected to the first type semiconductor layer  152   a  and the second type semiconductor layer  152   b  respectively. 
     In the present embodiment, the plurality of electrodes  156   a  and  156   b  are located on the same side of the first type semiconductor layer  152   a . That is, the light-emitting diode element  150  is a horizontal light-emitting diode. In addition, the light-emitting diode element  150  further includes an insulating layer  151  disposed on the first type semiconductor layer  152   a  and the second type semiconductor layer  152   b  and having a plurality of openings  151   a  and  151   b  respectively overlapping the first type semiconductor layer  152   a  and the second type semiconductor layer  152   b , wherein the plurality of electrodes  156   a  and  156   b  are electrically connected to the first type semiconductor layer  152   a  and the second type semiconductor layer  152   b  through the plurality of openings  151   a  and  151   b , respectively. 
     It should be noted that the first embodiment of the present disclosure further includes a plurality of connection patterns  158   a  and  158   b , and the materials of the plurality of connection patterns  158   a ,  158   b  include hot fluidity conductive materials. The hot fluidity conductive materials can flow after being heated. The temperature resistance of the active device substrate A and the sacrificial material layer  140  is higher than the temperature resistance of the hot fluidity conductive material. For example, in the present embodiment, the material of the hot fluidity conductive material may include indium (In), tin (Sn), other suitable materials, or a combination thereof, but the disclosure is not limited thereto. 
     The plurality of connection patterns  158   a  and  158   b  can be forming on at least one of the plurality of electrodes  156   a  and  156   b  and the plurality of plurality of pads  130   a  and  130   b . In other words, the plurality of connection patterns  158   a  and  158   b  can be disposed between of the plurality of electrodes  156   a  and  156   b  and the plurality of plurality of pads  130   a  and  130   b , and may be having three models. First model, the plurality of connection patterns  158   a  and  158   b  are as one portion of the light-emitting diode element  150 . Second model, the plurality of connection patterns  158   a  and  158   b  are respectively disposed on the plurality of pads  130   a  and  130   b . Third model, one portion of the plurality of connection patterns  158   a  and  158   b  are respectively disposed on the plurality of pads  130   a  and  130   b , and another portion of the plurality of connection patterns  158   a  and  158   b  are as one portion of the light-emitting diode element  150 . Embodiments of the present disclosure are description below with the first model as a preferably exemplary embodiment, but not limited thereto. Other models of the embodiments can be analogous. The plurality of connection patterns  158   a  and  158   b  of the light-emitting diode element  150  are respectively disposed on the plurality of electrodes  156   a  and  156   b . For example, in the embodiment, the connection patterns  158   a  and  158   b  are not only disposed on the electrodes  156   a  and  156   b , but also disposed on the stacked sidewall constituted by the first type semiconductor layer  152   a , the second type semiconductor layer  152   b , and the active layer  154 , but the disclosure is not limited thereto. 
     Referring to  FIG. 1A  and  FIG. 1B , next, the sacrificial material layer  140  in the one model is patterned to form the sacrificial pattern layer  142 , and a plurality of gaps g are formed between the plurality of connection patterns  158   a  and  158   b  and the plurality of pads  130   a  and  130   b , wherein the sacrificial pattern layer  142  exposes at least a portion of each of the plurality of pads  130   a  and  130   b . When in the second model, the plurality of gaps g are formed between the plurality of electrodes  156   a  and  156   b  and the plurality of pads  130   a  and  130   b . In other words, the plurality of gaps g are formed between the plurality of connection patterns  158   a  and  158   b  and the plurality of pads  130   a  and  130   b  or between the plurality of pads  130   a  and  130   b  and the plurality of electrodes  156   a  and  156   b.    
     For example, in the embodiment, the sacrificial material layer  140  is over-etched by using the light-emitting diode element  150  as a mask to form the sacrificial pattern layer  142 . There are a plurality of gaps g between the sidewall  142   a  of the sacrificial pattern layer  142 , the connection patterns  158   a  and  158   b , and the plurality of pads  130   a  and  130   b . In this embodiment, the vertical projection of the sacrificial pattern layer  142  on the substrate  110  may be within a vertical projection of the light-emitting diode element  150  on the substrate  110 , and the area of the vertical projection of the sacrificial pattern layer  142  on the substrate  110  may be less than the area of the vertical projection of the light-emitting diode element  150  on the substrate  110 , but the disclosure is not limited thereto. 
     Referring to  FIG. 1B  and  FIG. 1C , a heating process is then performed to make the plurality of connection patterns  158   a  and  158   b  become flowable, and the flowable connection patterns  158   a  and  158   b  flow downward by gravity, and are respectively electrically connected to the at least one of the plurality to pads  130   a  and  130   b  and the plurality of electrodes  156   a  and  156   b . The above heating process may be local heating or global heating depending on actual needs. For example, local heating may be performed by using laser welding; global heating may be performed by using a heating oven or a hot plate; however, the present disclosure is not limited thereto. At the present stage, the light-emitting apparatus  100  of the present embodiment is completed. In the present embodiment, the light-emitting apparatus  100  is, for example, a display apparatus. However, the present disclosure is not limited thereto. In other embodiments, the light-emitting apparatus  100  may also be an electronic apparatus that provides an illumination beam, such as but not limited to: a backlight. 
     It should be mentioned that, in this embodiment, the sacrificial material layer  140  under the light-emitting diode element  150  is patterned by using the light-emitting diode element  150  as a mask to form the sacrificial pattern layer  142 ; then, the connection patterns  158   a  and  158   b  inherently belonging to the light-emitting diode element  150  are respectively flowed onto the pads  130   a  and  130   b  of the active device substrate A to electrically connect the light-emitting diode element  150  and the active device substrate A. In this manner, the alignment accuracy requirement between the plurality of light-emitting diode elements  150  that are mass transferred and the plurality of pads  130   a  and  130   b  of the active device substrate A can be reduced, thereby improving the yield rate of the light-emitting apparatus  100 . 
     Referring to  FIG. 1C , the light-emitting apparatus  100  includes a substrate  110 , a plurality of pads  130   a  and  130   b , a sacrificial pattern layer  142 , and a light-emitting diode element  150 . The plurality of pads  130   a  and  130   b  are disposed on the substrate  110 . The sacrificial pattern layer  142  is at least disposed in a region R between the plurality of pads  130   a  and  130   b  and has a sidewall  142   a . The light-emitting diode element  150  is disposed on the sacrificial pattern layer  142 . The sacrificial pattern layer  142  is disposed between the first type semiconductor layer  152   a  of the light-emitting diode element  150  and the substrate  110 . The connection patterns  158   a  and  158   b  cover the sidewall  142   a  of the sacrificial pattern layer  142  and are electrically connected to the at least one of the plurality of pads  130   a  and  130   b  and the plurality of electrodes  156   a  and  156   b . In the first model, the connection patterns  158   a  and  158   b  cover the sidewall  142   a  of the sacrificial pattern layer  142  and are electrically connected to the at least one of the plurality of pads  130   a  and  130   b , but not limited thereto. In this embodiment, the connection patterns  158   a  and  158   b  may be in contact with the sidewall  142   a  of the sacrificial pattern layer  142  and the surfaces  130   a   1  and  130   b   1  of the plurality of pads  130   a  and  130   b , but the disclosure is not limited thereto. 
     In the present embodiment, the active layer  154  of the light-emitting diode element  150  may be disposed between the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150  and the sacrificial pattern layer  142 . That is, in the present embodiment, the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150  may optionally face upward. However, the present disclosure is not limited thereto, and according to other embodiments, the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150  may face downward, as exemplified below with other  FIG. 2A  through  FIG. 2C . 
       FIG. 2A  to  FIG. 2C  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a second embodiment of the present disclosure. The manufacturing process of a light-emitting apparatus  100 A of the second embodiment is similar to the manufacturing process of the light-emitting apparatus  100  of the first embodiment, and the main difference between the two is that the manner in which the light-emitting diode elements  150  are disposed on the active device substrate A is different, which will be specifically described with reference to  FIG. 2A  to  FIG. 2C . 
     Referring to  FIG. 2A , first, an active device substrate A is provided. The active device substrate A includes the substrate  110  and the plurality of pads  130   a  and  130   b  disposed on the substrate  110 . In the present embodiment, a distance H 1  between the surface  130   a   1  of the pad  130   a  and the substrate  110  may be optionally greater than the distance H 2  between the surface  130   b   1  of the pad  130   b  and the substrate  110 . That is, the thickness D 1  of the pad  130   a  may be greater than the thickness D 2  of the pad  130   b.    
     Referring to  FIG. 2A , then the sacrificial material layer  140  is formed on the substrate  110  to cover the plurality of pads  130   a  and  130   b . Thereafter, the light-emitting diode element  150  is disposed on the sacrificial material layer  140 . The height difference between the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150  can be compensated by the pads  130   a  and  130   b  having different thicknesses. In this manner, the thickness of a portion of the sacrificial material layer  140  sandwiched between the connection pattern  158   a  and the pad  130   a  can be substantially equal to the thickness of a portion of the sacrificial material layer  140  sandwiched between the connection pattern  158   b  and the pad  130   b  to facilitate subsequent patterning of the sacrificial material layer  140 . 
     Referring to  FIG. 2A  and  FIG. 2B , next, the sacrificial material layer  140  is patterned to form the sacrificial pattern layer  142 , and a plurality of gaps g are formed between the plurality of connection patterns  158   a  and  158   b  and the plurality of pads  130   a  and  130   b  or between the plurality of pads  130   a  and  130   b  and the plurality of electrodes  156   a  and  156   b . When in the first model, the plurality of gaps g are formed between the plurality of connection patterns  158   a  and  158   b  and the plurality of pads  130   a  and  130   b . When in the second model, the plurality of gaps g are formed between the plurality of pads  130   a  and  130   b  and the plurality of electrodes  156   a  and  156   b . Wherein the sacrificial pattern layer  142  exposes at least a portion of each of the plurality of pads  130   a  and  130   b . As shown in  FIG. 2A , in the embodiment, since the thickness of the portion of the sacrificial material layer  140  sandwiched between the connection pattern  158   a  and the pad  130   a  is substantially equal to the thickness of the portion of the sacrificial material layer  140  sandwiched between the connection pattern  158   b  and the pad  130   b , when the sacrificial material layer  140  is over-etched by using the light-emitting diode element (LED)  150  as a mask, a plurality of gaps g can be easily formed between the connection pattern  158   a  and the pad  130   a  and between the connection pattern  158   b  and the pad  130   b  without easily occurring undesirable phenomena (for example, but not limited to, a gap g has been formed between the connection pattern  158   b  and the pad  130   b , but a gap g has not been formed between the connection pattern  158   a  and the pad  130   a ). 
     Referring to  FIG. 2B  and  FIG. 2C , a heating process is then performed to make the plurality of connection patterns  158   a  and  158   b  become flowable, and the flowable connection patterns  158   a  and  158   b  flow downward by gravity, and are respectively electrically connected to the plurality of pads  130   a  and  130   b  in the first model. When in the second model, a heating process is then performed to make the plurality of connection patterns  158   a  and  158   b  become flowable, and the flowable connection patterns  158   a  and  158   b  flow upward by transfer LED&#39;s  150  force, and are respectively electrically connected to the plurality of electrodes  156   a  and  156   b . At the present stage, the light-emitting apparatus  100 A of the present embodiment is completed. 
     Referring to  FIG. 2C , the light-emitting apparatus  100 A of the present embodiment is similar to the light-emitting apparatus  100  of the first embodiment. The main difference between the two is that the electrodes  156   a  and  156   b  of the light-emitting diode element  150  are disposed between the active layer  154  of the light-emitting diode element  150  and the sacrificial pattern layer  142 . That is, in the present embodiment, the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150  may optionally face downward. In addition, in the present embodiment, the sacrificial pattern layer  142  not only contacts the connection pattern  142  but also contacts the insulating layer  151  between the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150 . 
       FIG. 3A  to  FIG. 3C  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a third embodiment of the present disclosure. The manufacturing process of a light-emitting apparatus  100 B of the third embodiment is similar to the manufacturing process of the light-emitting apparatus  100 A of the second embodiment, and the main difference between the two is that the manner of compensating for the height difference between the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150  in the third embodiment is different from the manner of compensating for the height difference between the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150  in the second embodiment, which will be specifically described below with reference to  FIG. 3A  to  FIG. 3C . 
     Referring to  FIG. 3A , first, the active device substrate A is provided. The active device substrate A includes the substrate  110  and the plurality of pads  130   a  and  130   b  disposed on the substrate  110 . Different from the second embodiment, the active device substrate A of the present embodiment further includes an auxiliary conductive pattern  170  disposed on the pad  130   a  and electrically connected to the pad  130   a . Specifically, the active device substrate A further includes a first dielectric layer  160 . The first dielectric layer  160  is disposed on the plurality of pads  130   a  and  130   b  and has a first contact via  162 . The auxiliary conductive pattern  170  is disposed on the first dielectric layer  160  and is electrically connected to the pad  130   a  through the first contact via  162 . In addition, the first dielectric layer  160  also has a second contact via  164  that overlaps the pad  130   b.    
     Referring to  FIG. 3A , the sacrificial material layer  140  is formed on the substrate  110  to cover the plurality of pads  130   a  and  130   b . In the present embodiment, the sacrificial material layer  140  is disposed on the auxiliary conductive pattern  170  and the first dielectric layer  160 , and is disposed above the plurality of pads  130   a  and  130   b . Then, the light-emitting diode element  150  is disposed on the sacrificial material layer  140 . The arrangement of the auxiliary conductive pattern  170  can compensate for the height difference between the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150 . That is, the thickness of the portion of the sacrificial material layer  140  sandwiched between the connection pattern  158   a  and the auxiliary conductive pattern  170  may be substantially equal to the thickness of the portion of the sacrificial material layer  140  sandwiched between the connection pattern  158   b  and the pad  130   b  to facilitate subsequent patterning of the sacrificial material layer  140 . 
     Referring to  FIG. 3A  and  FIG. 3B , then the sacrificial material layer  140  is patterned to form the sacrificial pattern layer  142 , and the plurality of gaps g are formed between the plurality of connection patterns  158   a  and  158   b  of the light-emitting diode element  150  and the auxiliary conductive pattern  170  and the pad  130   b , wherein the sacrificial pattern layer  142  exposes the auxiliary conductive patterns  170  and at least a portion of each of and the pads  130   b . As shown in  FIG. 3A , in the embodiment, since the thickness of the portion of the sacrificial material layer  140  sandwiched between the connection pattern  158   a  and the auxiliary conductive pattern  170  is substantially equal to the thickness of the portion of the sacrificial material layer  140  between the connection pattern  158   b  and the pad  130   b , when the sacrificial material layer  140  is over-etched by using the light-emitting diode element  150  as a mask, the plurality of gaps g can be easily formed between the connection pattern  158   a  and the pad  130   a  and between the connection pattern  158   b  and the pads  130   b  without easily occurring undesirable phenomena (for example, but not limited to, a gap g has been formed between the connection pattern  158   b  and the pad  130   b , but a gap g has not been formed between the connection pattern  158   a  and the pad  130   a ). 
     Referring to  FIG. 3B  and  FIG. 3C , then a heating process is performed to make the plurality of connection patterns  158   a  and  158   b  flowable, and the flowable connection patterns  158   a  and  158   b  flow downward by gravity, and are electrically connected to the auxiliary conductive pattern  170  and the pad  130   b  respectively. In the present embodiment, the connection pattern  158   a  including the hot fluidity conductive material is in contact with the auxiliary conductive pattern  170 , and the auxiliary conductive pattern  170  can be regarded as a pad. The sacrificial pattern layer  142  is at least disposed in a region R between the auxiliary conductive pattern  170  and the pad  130   b . In addition, in the embodiment, the other connection pattern  158   b  is electrically connected to the second contact via  164  of the first dielectric layer  160  and the pad  130   b . At the present stage, the light-emitting apparatus  100 B of the present embodiment is completed. 
       FIG. 4A  to  FIG. 4C  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a fourth embodiment of the present disclosure. The manufacturing process of a light-emitting apparatus  100 C of the fourth embodiment is similar to the manufacturing process of the light-emitting apparatus  100 B of the third embodiment, and the main difference between the two is that the manner of compensating for the height difference between the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150  in the fourth embodiment is different from the manner of compensating for the height difference between the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150  in the third embodiment, which will be described below with reference to  FIG. 4A  to  FIG. 4C . 
     Referring to  FIG. 4A , first, the active device substrate A is provided. The active device substrate A includes the substrate  110  and the plurality of pads  130   a  and  130   b  disposed on the substrate  110 . Unlike the third embodiment, the active device substrate A of the present embodiment does not include the auxiliary conductive pattern  170 . 
     Referring to  FIG. 4A , the sacrificial material layer  140  is formed on the substrate  110  to cover the plurality of pads  130   a  and  130   b . Then, the light-emitting diode element  150  is disposed on the sacrificial material layer  140 . Different from the third embodiment, the light-emitting diode element  150  of the present embodiment is different from the light-emitting diode element  150  of the third embodiment. Specifically, the light-emitting diode element  150  of the present embodiment further includes an auxiliary electrode  159  disposed on one of the electrodes  156   a  of the light-emitting diode element  150  and electrically connected to the electrode  156   a . When the light-emitting diode element  150  is disposed on the sacrificial material layer  140 , the surface  159   a  of the pad  130   a  of the auxiliary electrode  159  facing the active device substrate A can be substantially coplanar with the surface  156   b   1  of the pad  130   b  of the other electrode  156   b  facing of the active device substrate A. The connection pattern  158   a  and the connection pattern  158   b  are respectively disposed on the surface  159   a  of the auxiliary electrode  159  and the surface  156   b   1  of the electrode  156   b , and are electrically connected to the auxiliary electrode  159  and the electrode  156   b , respectively. Since the connection pattern  158   a  is disposed on the auxiliary electrode  159  for compensating for the height difference between the electrodes  156   a  and  156   b , the thickness of the portion of the sacrificial material layer  140  sandwiched between the connection pattern  158   a  and the pad  130   a  can be substantially equal to the thickness of the portion of the sacrificial material layer  140  between the connection pattern  158   b  and the pad  130   b  to facilitate subsequent patterning of the sacrificial material layer  140 . 
     Referring to  FIG. 4A  and  FIG. 4B , next, the sacrificial material layer  140  is patterned to form the sacrificial pattern layer  142 , and the plurality of gaps g are formed between the plurality of connection patterns  158   a  and  158   b  of the light-emitting diode element  150  and the plurality of pads  130   a  and  130   b , wherein the sacrificial pattern layer  142  exposes at least a portion of each of the plurality of pads  130   a  and  130   b . As shown in  FIG. 4A , in the present embodiment, the auxiliary electrode  159  of the light-emitting diode element  150  compensates for the height difference between the electrode  156   a  and the electrode  156   b , such that the thickness of the portion of the sacrificial material layer  140  sandwiched between the connection pattern  158   a  and the pad  130   a  is substantially equal to the thickness of the portion of the sacrificial material layer  140  sandwiched between the connection pattern  158   b  and the pad  130   b . Therefore, when the sacrificial material layer  140  is over-etched by using the light-emitting diode element  150  as a mask, the plurality of gaps g can be easily formed between the connection pattern  158   a  and the pad  130   a  and between the connection pattern  158   b  and the pad  130   b  without easily occurring undesirable phenomena (for example, but not limited to, a gap g has been formed between the connection pattern  158   b  and the pad  130   b , but a gap g has not been formed between the connection pattern  158   a  and the pad  130   a ). 
     Referring to  FIG. 4B  and  FIG. 4C , then a heating process is performed to make the plurality of connection patterns  158   a  and  158   b  become flowable, and the flowable connection patterns  158   a  and  158   b  flow downward by gravity, and are electrically connected to the plurality of pads  130   a  and  130   b  respectively. At the present stage, the light-emitting apparatus  100 C of the present embodiment is completed. In some embodiment, a distance between a surface of one of the pads  130   a  and  130   b  in contact with one of the connection patterns  158   a  and  158   b  and the substrate  110  is substantially equal to a distance between a surface of another of the pads  130   a  and  130   b  in contact with another of the connection patterns  158   a  and  158   b  and the substrate  110 . 
     The first to fourth embodiments describe the manufacturing process of one pixel of the light-emitting apparatuses  100 ,  100 A to  100 C as an example. Those having ordinary skill in the art should be able to understand that the manufacturing process of the one pixel can be used to simultaneously manufacture a plurality of pixels, which will be exemplified below with reference to  FIG. 5A  to  FIG. 5C  and  FIG. 6 . 
       FIG. 5A  to  FIG. 5C  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a fifth embodiment of the present disclosure.  FIG. 6  is a schematic top view showing a light-emitting apparatus according to a fifth embodiment of the present disclosure.  FIG. 5C  corresponds to the cross-sectional line I-I′ taken from  FIG. 6 .  FIG. 6  depicts the substrate  110  and the light-emitting diode element  150  of  FIG. 5C , while the other components of  FIG. 5C  are omitted. 
     Referring to  FIG. 5A , first, the active device substrate A is provided. The active device substrate A includes the substrate  110  and a plurality of pad sets  130  disposed on the substrate  110 . Each pad set  130  includes the plurality of pads  130   a  and  130   b . Next, the sacrificial material layer  140  is formed on the substrate  110  to cover the plurality of pad sets  130 . Then, the plurality of light-emitting diode elements  150  are disposed on the sacrificial material layer  140 . The plurality of light-emitting diode elements  150  are bonded to the active device substrate A through the sacrificial material layer  140 . 
     Referring to  FIG. 5A  and  FIG. 5B , next, the sacrificial material layer  140  is patterned to form the sacrificial pattern layer  142 , and the plurality of gaps g are formed between the plurality of connection patterns  158   a  and  158   b  and the plurality of pads  130   a  and  130   b , wherein the sacrificial pattern layer  142  exposes at least a portion of each of the plurality of pads  130   a  and  130   b.    
     Referring to  FIG. 5B ,  FIG. 5C   FIG. 6 , then a heating process is performed to make the plurality of connection patterns  158   a  and  158   b  of the plurality of light-emitting diode elements  150  become flowable, and the flowable connection patterns  158   a  and  158   b  flow downward by gravity, and are electrically connected to the plurality of pads  130   a  and  130   b  respectively. At the present stage, the light-emitting apparatus  100 D of the present embodiment is completed. 
     The first to the fifth embodiments describe the fabrication of the light-emitting apparatuses  100 ,  100 A to  100 D directly by using the connection patterns  158   a  and  158   b  including the hot fluidity conductive material. However, the present disclosure is not limited thereto, and the light-emitting diode element  150  of the connection patterns  158   a  and  158   b  including the hot fluidity conductive material may also be used to repair the completed light-emitting apparatus, which will be exemplified with reference to  FIG. 7A  to  FIG. 7F ,  FIG. 8A  to  FIG. 8F ,  FIG. 9A  to  FIG. 9F  and  FIG. 10A  to  FIG. 10F . 
       FIG. 7A  to  FIG. 7F  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a sixth embodiment of the present disclosure.  FIG. 8A  to  FIG. 8F  are schematic top views showing a manufacturing process of a light-emitting apparatus according to a sixth embodiment of the present disclosure.  FIG. 8A  to  FIG. 8F  correspond to the cross-sectional lines I-I′ and II-II′ taken from  FIG. 7A  to  FIG. 7F , respectively.  FIG. 8A  to  FIG. 8F  illustrate the light-emitting diode element  150 , the interconnection patterns  182  and  184 , and the substrate  110  of  FIG. 7A  to  FIG. 7F , and other components in  FIG. 7A  to  FIG. 7F  are omitted. 
     Referring to  FIG. 7A  and  FIG. 8A ,  FIG. 7A  and  FIG. 8A  illustrate a light-emitting apparatus manufactured by a conventional method. Specifically, a light-emitting apparatus that has been completed by using a conventional method includes an active device substrate A, a plurality of light-emitting diode elements  150 - 1  and  150 - 2 , and a plurality of interconnection patterns  182  and  184 . 
     Referring to  FIG. 7A  and  FIG. 8A , after the light-emitting apparatus has been completed by the conventional method, then the light-emitting apparatus is detected, and it is found that the light-emitting diode element  150 - 2  is abnormal and/or the electrical connection with the active device substrate A is poor. Referring to  FIG. 7A ,  FIG. 7B ,  FIG. 8A , and  FIG. 8B , thereafter the light-emitting diode element  150 - 2  is removed. When the light-emitting diode element  150 - 2  is removed, a portion of the interconnection pattern  182  disposed on the light-emitting diode element  150 - 2  and a portion of the interconnection pattern  184  disposed on the light-emitting diode element  150 - 2  are removed along with the light-emitting diode element  150 - 2 , and another portion of the interconnection pattern  182  disposed on the second dielectric layer  190  and another portion of the interconnection pattern  184  disposed on the second dielectric layer  190  are left on the substrate  110  as shown in  FIG. 7B  and  FIG. 8B . 
     Referring to  FIG. 7C  and  FIG. 8C , next, the sacrificial material layer  140  is formed on the substrate  110  to cover the plurality of pads  130   a  and  130   b . In this embodiment, the sacrificial material layer  140  is formed on a portion of the second dielectric layer  190  overlapping the original light-emitting diode element  150 - 2  and the partial interconnection pattern  182  and the partial interconnection pattern  184  on both sides of the light-emitting diode element  150 - 2 . 
     Referring to  FIG. 7D  and  FIG. 8D , next, the light-emitting diode element  150 - 3  is disposed on the sacrificial material layer  140 . The light-emitting diode element  150 - 3  is bonded to the active device substrate A through the sacrificial material layer  140 . The light-emitting diode element  150 - 3  also includes the plurality of connection patterns  158   a  and  158   b.    
     Referring to  FIG. 7D ,  FIG. 7E ,  FIG. 8D , and  FIG. 8E , then the sacrificial material layer  140  is patterned to form the sacrificial pattern layer  142 , and the plurality of gaps g are formed between the plurality of connection patterns  158   a  and  158   b  of the light-emitting diode element  150  and the partial interconnection patterns  182  and  184 , wherein the sacrificial pattern layer  142  exposes at least a portion of each of the partial interconnection patterns  182  and  184 . For example, in the embodiment, the sacrificial material layer  140  is over-etched by using the light-emitting diode element  150 - 3  as a mask to form the sacrificial pattern layer  142 . When the sacrificial material layer  140  is subjected to an over-etching process, there are the plurality of gaps g between the sidewall  142   a  of the sacrificial pattern layer  142  and the interconnection patterns  182  and  184 . 
     Referring to  FIG. 7F  and  FIG. 8F , next, a heating process is performed to make the plurality of connection patterns  158   a  and  158   b  become flowable, and the flowable connection patterns  158   a  and  158   b  flow downward by gravity, and are electrically connected to the interconnection patterns  182  and  184  respectively remained on the substrate  110 . In the present embodiment, the connection patterns  158   a  and  158   b  of the light-emitting diode element  150 - 3  are in contact with and electrically connected to the interconnection patterns  182  and  184 . The interconnection patterns  182  and  184  can also be regarded as pads. The sacrificial pattern layer  142  is at least disposed in a region R between the interconnection pattern  182  and the interconnection pattern  184 . The connection patterns  158   a  and  158   b  of the light-emitting diode element  150 - 3  are electrically connected to the pads  130   a  and  130   b  through the interconnection patterns  182  and  184 . At the present stage, the repaired light-emitting apparatus  100 E is completed. 
     It should be noted that in the present embodiment, the electrode  156   b  of the light-emitting diode element  150 - 1  and the electrode  156   b  of the light-emitting diode element  150 - 3  for repair are electrically connected to each other. That is to say, the normal light-emitting diode element  150 - 1  and the light-emitting diode element  150 - 3  for repair belong to the same pixel. However, the present disclosure is not limited thereto, and according to other embodiments, the electrode  156   b  of the normal light-emitting diode element  150 - 1  and the electrode  156   b  of the light-emitting diode element  150 - 3  for repair are also electrically independent from each other; that is, the normal light-emitting diode element  150 - 1  and the light-emitting diode element  150 - 3  for repair may also belong to different pixels. 
     As shown in  FIG. 7F  and  FIG. 8F , in the present embodiment, the light-emitting diode element  150 - 3  for replacing the original light-emitting diode element  150 - 2  is disposed at the position where the original light-emitting diode element  150 - 2  is disposed. That is, in the present embodiment, the new light-emitting diode element  150 - 3  overlaps the pads  130   a  and  130   b . However, the present disclosure is not limited thereto. In other embodiments, the light-emitting diode element  150 - 3  for replacing the original light-emitting diode element  150 - 2  may not be disposed at the position where the original light-emitting diode element  150 - 2  is disposed, which will be exemplified below with reference to  FIG. 9A  to  FIG. 9F  and  FIG. 10A  to  FIG. 10F . 
       FIG. 9A  to  FIG. 9F  are schematic cross-sectional views showing a manufacturing process of a light-emitting apparatus according to a seventh embodiment of the present disclosure.  FIG. 10A  to  FIG. 10F  are schematic top views showing a manufacturing process of a light-emitting apparatus according to a seventh embodiment of the present disclosure.  FIG. 9A  to  FIG. 9F  correspond to the cross-sectional lines I-I′ and II-II′ taken from  FIG. 10A  to  FIG. 10F , respectively.  FIG. 10A  to  FIG. 10F  illustrate the light-emitting diode element  150 , the interconnection patterns  182  and  184 , and the substrate  110  in  FIG. 9A  to  FIG. 9F , while other components in  FIG. 9A  to  FIG. 9F  are omitted. 
     Referring to  FIG. 9A  and  FIG. 10A , first, the active device substrate A is provided. The active device substrate A includes the substrate  110 , the driving circuit layer  120  disposed on the substrate  110 , the plurality of pads  130   a  and  130   b  electrically connected to the driving circuit layer  120 , and the second dielectric layer  190  disposed on the plurality of pads  130   a  and  130   b . The second dielectric layer  190  has contact vias  192  and  194  that overlap the plurality of pads  130   a  and  130   b , respectively. The light-emitting diode element  150 - 1  is disposed on the second dielectric layer  190 . The plurality of interconnection patterns  182  and  184  are respectively disposed on the plurality of electrodes  156   a  and  156   b  of the light-emitting diode element  150 - 1 , and are electrically connected to the plurality of pads  130   a  and  130   b  respectively through the contact vias  192  and  194  of the second dielectric layer  190 . Specifically, in the present embodiment, the interconnection patterns  182  and  184  have portions  182   a  and  184   a  that extend beyond the pads  130   a  and  130   b  without overlapping the pads  130   a  and  130   b.    
     Referring to  FIG. 9A  and  FIG. 10A , after the light-emitting apparatus is manufactured by using the conventional method, then the light-emitting apparatus is detected, and it is found that the light-emitting diode element  150 - 1  is abnormal and/or the electrical connection with the active device substrate A is poor. Referring to  FIG. 9A ,  FIG. 9B ,  FIG. 10A , and  FIG. 10B , then the light-emitting diode element  150 - 1  is removed. 
     Referring to  FIG. 9C  and  FIG. 10C , the sacrificial material layer  140  is formed on the substrate  110  to cover a portion  182   a  of the interconnection pattern  182  that does not overlap the pads  130   a  and  130   b  and a portion  184   a  of the interconnection pattern  184  that does not overlap the pad  130   b.    
     Referring to  FIG. 7D  and  FIG. 8D , next, the light-emitting diode element  150 - 3  is disposed on the sacrificial material layer  140 . The light-emitting diode element  150 - 3  is bonded to the active device substrate A through the sacrificial material layer  140 . The light-emitting diode element  150 - 3  also includes the plurality of connection patterns  158   a  and  158   b.    
     Referring to  FIG. 9D ,  FIG. 9E ,  FIG. 9D , and  FIG. 9E , then the sacrificial material layer  140  is patterned to form the sacrificial pattern layer  142 , and the plurality of gaps g are formed between the plurality of connection patterns  158   a  and  158   b  of the light-emitting diode element  150  and the partial interconnection patterns  182   a  and  184   a , wherein the sacrificial pattern layer  142  exposes at least a portion of each of the partial interconnection patterns  182   a  and  184   a.    
     Referring to  FIG. 9F  and  FIG. 10F , thereafter a heating process is performed to make the plurality of connection patterns  158   a  and  158   b  become flowable, and the flowable connection patterns  158   a  and  158   b  flow downward by gravity, and are electrically connected to a portion  182   a  of the interconnection pattern  182  not overlapping the pads  130   a  and  130   b  and a portion  184   a  of the interconnection pattern  184  not overlapping the pad  130   b  respectively. In the present embodiment, the connection patterns  158   a  and  158   b  of the light-emitting diode element  150 - 3  are in contact with and electrically connected to a portion  182   a  of the interconnection pattern  182  and a portion  184   a  of the interconnection pattern  184 . A portion  182   a  of the interconnection pattern  182  and a portion  184   a  of the interconnection pattern  184  can also be regarded as a pad. The sacrificial pattern layer  142  is at least disposed in a region R between the portion  182   a  of the interconnection pattern  182  and the portion  184   a  of the interconnection pattern  184 . The connection patterns  158   a  and  158   b  of the light-emitting diode element  150 - 3  are electrically connected to the pads  130   a  and  130   b  through the interconnection patterns  182  and  184 . At the present stage, the repaired light-emitting apparatus  100 F is completed. 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed embodiments without departing from the scope or spirit of the disclosure. In view of the foregoing, it is intended that the disclosure covers modifications and variations provided that they fall within the scope of the following claims and their equivalents.