Patent Description:
The display devices are becoming more widely used. Since mass production has recently become the tendency in the light-emitting diode industry, any increase in the yield of manufacturing light-emitting diodes, such as increasing the alignment accuracy. Therefore, the manufacturing method for the display devices may need to be continuously improved.

<CIT> discloses a method for manufacturing a display device, comprising: providing an array module having at least one first alignment mark and a first substrate; providing a light-emitting module having at least one second alignment mark and a second substrate; aligning the light-emitting module and the array module by the at least one first alignment mark and the at least one second alignment mark; and bonding the light-emitting module onto the array module. However, both the first alignment mark and the at least one second alignment mark are formed as protrusions. Accordingly, it is not disclosed that the at least one second alignment mark penetrates the second substrate.

It is a problem to be solved by the present invention to provide an enhanced method for manufacturing a display device as well as an enhanced display device enabling a higher alignment accuracy.

This problem is solved by a method for manufacturing a display device according to the invention as claimed by claim <NUM>, and by a display device according to the invention as claimed by claim <NUM>. Further advantageous embodiments are the subject-matter of the dependent claims.

The disclosure may be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:.

The display device of the present disclosure is described in detail in the following description. The drawings of different embodiments may use like and/or corresponding numerals to denote like and/or corresponding elements in order to clearly describe the present disclosure. However, the use of like and/or corresponding numerals in the drawings of different embodiments does not suggest any correlation between different embodiments. In addition, in this specification, expressions such as "first material layer disposed on/over a second material layer", may indicate the direct contact of the first material layer and the second material layer, or it may indicate a non-contact state with one or more intermediate layers between the first material layer and the second material layer. In the above situation, the first material layer may not be in direct contact with the second material layer.

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

The terms "about" and "substantially" typically mean +/- <NUM>% of the stated value, +/- <NUM>% of the stated value, +/- <NUM>% of the stated value, +/- <NUM>% of the stated value, +/-<NUM>% of the stated value, +/- <NUM>% of the stated value or +/- <NUM>% of the stated value. The stated value of the present disclosure is an approximate value. When there is no specific description, the stated value includes the meaning of "about" or "substantially".

It should be understood that, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers, portions and/or sections, these elements, components, regions, layers, portions and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, portion or section from another region, layer or section. Thus, a first element, component, region, layer, portion or section discussed below could be termed a second element, component, region, layer, portion or section without departing from the teachings of the present disclosure.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It should be appreciated that, in each case, the term, which is defined in a commonly used dictionary, should be interpreted as having a meaning that conforms to the relative skills of the present disclosure and the background or the context of the present disclosure, and should not be interpreted in an idealized or overly formal manner unless so defined.

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

In the description, relative terms such as "lower," "upper," "horizontal," "vertical,", "on,", "above," "below," "up," "down," "top" and "bottom" as well as derivative thereof (e.g., "horizontally," "downwardly," "upwardly," etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as "connected" and "interconnected," refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

The present disclosure provides a method for manufacturing a display device. Refer to <FIG>, which is a flow chart <NUM> of a method for manufacturing a display device according to the present invention. The flow chart <NUM> includes multiple steps <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and <NUM>. Each of steps may correspond to <FIG> or <FIG>. <FIG> illustrate the steps in the top view. <FIG> illustrate the steps in the cross-sectional view. In some embodiments, other steps may be appropriately added before or after above the steps. In some embodiments, the above partial steps may be appropriately deleted or replaced. In some embodiments, the above sequence of steps can be changed or modulated as needed.

The method for manufacturing the display device includes the step <NUM> of providing an array module having at least one first alignment mark and a light-emitting module having at least one second alignment mark. As shown in <FIG>, an array module <NUM> and a light-emitting module <NUM> are provided. As shown in <FIG>, the array module <NUM> includes a first substrate <NUM>. The first substrate <NUM> may include a glass substrate, a ceramic substrate, a plastic substrate or another suitable substrate, but not limited. The first substrate <NUM> may include polyimide (PI), polycarbonate (PC), or polyethylene terephthalate (PET), but not limited thereto. The array module <NUM> includes a plurality of pads <NUM>. The pads <NUM> are disposed on the first substrate <NUM>. The material of the pad <NUM> may include copper (Cu), aluminum (Al), molybdenum (Mo), gold (Au), chromium (Cr), nickel (Ni), platinum (Pt), titanium (Ti), iridium (Ir), other suitable material, or the above alloy, but is not limited. As shown in <FIG>, the display device comprises a plurality of pixels P. <FIG> illustrates a pixel P that may correspond to (or be electrically connected to) six pads <NUM>, and a sub-pixel (correspond to one light-emitting element <NUM>) may respectively correspond to two pads <NUM>, but is not limited thereto. The dotted line may correspond to a position where the pixel (not shown in <FIG>) is expected to be bonded. As shown in <FIG>, one pixel P may include three sub-pixels, and a sub-pixel may respectively correspond to or electrically connected to two pads <NUM> after bonding (subsequent step <NUM> will be described). In other embodiments (not shown), a pixel P may correspond to (or be electrically connected to) four pads <NUM>, for example, one of the four pads <NUM> is a shared pad, the shared pad is electrically connected to three sub-pixels of the pixel P, and other pads may respectively correspond to (or be electrically connected to) three sub-pixels with different colors. In some embodiments, at least part of the pixel P may overlap with corresponding pads <NUM> in Z direction, and Z direction may defined as a normal direction of the first substrate <NUM> of the array module <NUM>. In some embodiments (shown in <FIG>), the array module <NUM> includes at least one first alignment mark <NUM> on the first substrate <NUM>.

As shown in <FIG>, the light-emitting module <NUM> includes a second substrate <NUM>. The second substrate <NUM> may be a carrier substrate or growth substrate, but is not limited. In some embodiments, the second substrate <NUM> may include a glass substrate, a ceramic substrate, a plastic substrate, a sapphire substrate or another suitable substrate, but is not limited. The growth substrate may include silicon or a sapphire substrate, which includes alumina oxide, GaP, GaAs, AlGaAs, SiC, Si, or another suitable material, but is not limited.

The light-emitting module <NUM> includes a plurality of light-emitting elements <NUM>. The light-emitting elements <NUM> may be disposed on the second substrate <NUM>. The light-emitting element <NUM> may be a red sub-pixel, a green sub-pixel or a blue sub-pixel, an infrared (IR) sub-pixel, or other sub-pixel with other colors. In some embodiments, the light-emitting element <NUM> may include light-emitting diode (LED), micro LED (µLED), mini LED, quantum dot (QD), quantum dot LED (QLED or QDLED) or other suitable element, but is not limited. In some embodiments, the light-emitting element <NUM> may emit blue light (or UV light), but is not limited. In some embodiments, the light-emitting element <NUM> may respectively emit the light with different colors (such as red, green, blue or other suitable colors). In some embodiments, the light-emitting module <NUM> may include the light conversion elements, the light conversion elements (such as quantum dot, but is not limited) may be disposed on or adjacent to the light-emitting module <NUM>.

As shown in <FIG>, the light-emitting module <NUM> includes at least one second alignment mark <NUM> on the second substrate <NUM>. In some embodiments, at least one pixel P may be disposed between two adjacent second alignment marks <NUM>, but not limited, the quantity of pixel P can be adjusted as needed.

In some embodiments, the position of the second alignment mark <NUM> of the light-emitting module <NUM> may correspond to the position of the first alignment mark <NUM> of the array module <NUM>. For example, four second alignment marks <NUM> of the light-emitting module <NUM> may respectively correspond to one of four first alignment marks <NUM> on the right part (or on the left part) of the array module <NUM>, but not limited. As shown in <FIG>, there is a first distance T1 between two adjacent first alignment marks <NUM> along the X direction, and there is a second distance T2 between two adjacent second alignment marks <NUM> along the X direction. X direction may be defined as a direction parallel to an extension direction of the long side of the first substrate <NUM>, but not limited. In some embodiments, the X direction may be defined as an arrangement direction of adjacent pixels. In some embodiments, the X direction may be defined as an arrangement direction of sub-pixels of the pixel P. Y direction may be perpendicular with Z direction and X direction. First distance T1 may be defined as a distance between a center of one of the first alignment marks <NUM> and a center of another first alignment mark <NUM> adjacent to the one of the first alignment marks <NUM> along the X direction (or Y direction). Second distance T2 may be defined as a distance between a center of one of the second alignment marks <NUM> and a center of another second alignment marks <NUM> adjacent to the one of the second alignment marks <NUM> along the X direction(or Y direction). In some embodiments, the ratio of the first distance T1 to the second distance T2 is in a range from <NUM> to <NUM>, but not limited. In some embodiments, the ratio of the first distance T1 to the second distance T2 is in a range from <NUM> to <NUM>. In addition, there is a distance T3 between two first alignment marks <NUM> which are respectively disposed on two sides of a diagonal line of the right part (or the left part) of the first substrate <NUM>, and there is a distance T4 between two second alignment marks <NUM> which are respectively disposed on two sides of diagonal line of the second substrate <NUM>. Distance T3 may be defined as a distance between a center of one of the first alignment marks <NUM> and a center of another first alignment mark <NUM> along a direction of the diagonal line. Distance T4 may be defined as a distance between a center of one of the second alignment marks <NUM> and a center of another second alignment marks <NUM> along a direction of the diagonal line. In some embodiments, the ratio of distance T3 to distance T4 is in a range from <NUM> to <NUM>, but not limited. In some embodiments, the ratio of distance T3 to distance T4 is in a range from <NUM> to <NUM>. When the ratio of distance T3 to distance T4 (or first distance T1 to second distance T2) is in the range mentioned above, the accuracy of bonding the array module <NUM> and the light-emitting module <NUM> may be increased.

In some embodiments, the distance between two adjacent first alignment marks <NUM> along the X direction is the same as or different from the distance between two adjacent first alignment marks <NUM> along the Y direction. In some embodiments, the distance between two adjacent second alignment marks <NUM> along the X direction (such as second distance T2) is the same as or different from the distance between two adjacent second alignment marks <NUM> along the Y direction.

As shown in <FIG>, the second alignment mark <NUM> has a width W1. The light-emitting element <NUM> has a width W2. The width W2 may be a maximum width of one of the light-emitting elements <NUM> in X direction. The width W1 may be a maximum width of one of the second alignment mark <NUM> in X direction. In some embodiments, the width W1 is less than or equal to the width W2. In some embodiments, the width W1 is greater than the width W2. In some embodiments, an area of the light-emitting element <NUM> may be defined as a lighting area of one sub-pixel operating at a highest grayscale in Z direction, but not limited. In some embodiments, an area of the light-emitting element <NUM> may defined as a lighting surface (such top surface of the light-emitting element <NUM>) of one sub-pixel, but not limited. In some embodiments, an area of the light-emitting element <NUM> may be defined by the openings of the light blocking layer <NUM> (shown in <FIG>). In some embodiments, an area of the second alignment mark <NUM> is less than an area of one pixel of the display device.

The method for manufacturing the display device includes the step <NUM> that aligning the array module <NUM> and the light-emitting module <NUM> by the first alignment mark <NUM> and the second alignment mark <NUM>. As shown in <FIG>, the light-emitting module <NUM> may approach (or be transferred to) the right part (or left part) of the array module <NUM>. In some embodiments, a length of the second alignment mark <NUM> is greater than a length of the first alignment mark <NUM>. In some embodiments, an area of the second alignment mark <NUM> is greater than an area of the first alignment mark <NUM>.

The method for manufacturing the display device includes the step <NUM> that approaching the at least one second alignment mark <NUM> with the at least one first alignment mark <NUM> into a detecting region S. Refer to <FIG>, which is an enlarged view of region R shown in <FIG>. As shown in <FIG>, the detecting region S may be a region that can be detected by a charge-coupled device (CCD) camera (not shown) or other suitable image equipment (or camera equipment), but not limited. When at least one of the second alignment mark <NUM> and the first alignment mark <NUM> is outside the detecting region S, the light-emitting module <NUM> or the array module <NUM> may be transferred, so that the second alignment mark <NUM> and the first alignment mark <NUM> would be inside the detecting region S.

The method for manufacturing the display device includes the step <NUM> that detecting the distance between the second alignment mark <NUM> and the first alignment mark <NUM>, and comparing the distance with a predetermined value. Refer to <FIG>, which is an enlarged view of the region R shown in <FIG>. After the second alignment mark <NUM> and the first alignment mark <NUM> are inside the detecting region S, the distance between the first alignment mark <NUM> and the second alignment mark <NUM> is detected by the CCD camera or other suitable image equipment (or camera equipment), but not limited, and the distance between the first alignment mark <NUM> and the second alignment mark <NUM> will be compared with the predetermined value. In some embodiments (shown in <FIG>), the pitch between the pixels P is a pixel pitch W3, and the predetermined value is less than or equal to half of the pixel pitch W3. The pixel pitch W3 may be a distance between the centers (left sides or right sides) of the two adjacent pixels P, but not limited. For example, the pixel pitch P may be a distance between the centers (left sides or right sides) of two adjacent sub-pixels with the same color.

The method for manufacturing the display device includes the step <NUM> that determining whether the distance is less than or equal to the predetermined value. For example, the step <NUM> includes determining whether the distance X1 along the X direction (or the distance Y1 along the Y direction) is less than or equal to the predetermined value. As shown in <FIG>, the distance X1 is the distance between the first alignment mark <NUM> and the second alignment mark <NUM> along the X direction, and the distance Y1 is the distance between the first alignment mark <NUM> and the second alignment mark <NUM> along the Y direction.

If the distance X1 (or the distance Y1) is greater than the predetermined value, the step <NUM> will be performed. The step <NUM> includes reducing the distance between the second alignment mark <NUM> and the first alignment mark <NUM>. In addition, the step <NUM> includes adjusting the position of the array module <NUM> or the light-emitting module <NUM>, so that the first alignment mark <NUM> would be aligned with (or overlapped with) the second alignment mark <NUM>. In some embodiments, the step <NUM> includes approaching the array module <NUM> or the light-emitting module <NUM> along the X direction (or the Y direction or other directions), so that the first alignment mark <NUM> would be aligned with (or overlapped with) the second alignment mark <NUM>, but not limited. After the performing of the step <NUM>, the step <NUM> is performed to detect the distance between the first alignment mark <NUM> and the second alignment mark <NUM> along the X direction (or the Y direction or other directions).

In some embodiments, if both the distance X1 and the distance Y1 are less than or equal to the predetermined value, the step <NUM> will be performed. The step <NUM> includes bonding the light-emitting module <NUM> onto the array module <NUM>. As shown in <FIG>, after bonding the light-emitting module <NUM> onto the array module <NUM>, the second substrate <NUM> may be disposed on the right part (left part or other part) of the first substrate <NUM>, but not limited. Moreover, the light-emitting elements <NUM> may be electrically connected to the corresponding pad <NUM>. In some embodiments, the light-emitting elements <NUM> may respectively overlap with part of the corresponding pad <NUM> in Z direction.

In some embodiments, the predetermined value is less than or equal to half of the pixel pitch W3 of the pixels P. In some embodiments, the predetermined value is equal to the width W2. In some embodiments, when the predetermined value is in the range mentioned above, the production yield of bonding the array module <NUM> and the light-emitting module <NUM> may be increased.

In some embodiments, the second substrate <NUM> may be removed (as shown in <FIG>), and the light-emitting elements <NUM> are disposed on (or bonded onto) the pad <NUM>. In some embodiments, the second substrate <NUM> may be removed by a laser or other suitable methods. In some embodiments, the second substrate <NUM> may not be removed, and the second substrate <NUM> and the light-emitting elements <NUM> may disposed on the array module <NUM>. The process shown in <FIG> may be repeated so that another light-emitting module <NUM> may be disposed on (or bonded on) the another part (such as left part) of the array module <NUM>.

The process shown in <FIG> may be used in mass production of the display device, but not limited. For example, nine pixels may be disposed on (or bonded onto) the corresponding pads <NUM> in same bonding process, but not limited. In some embodiments, the second substrate <NUM> may be used as a growth substrate, and the second alignment marks may be disposed on (or formed on) the second substrate <NUM>. In some embodiments, the second substrate <NUM> may be used as a carrier substrate, and the light-emitting elements <NUM> may be transferred onto the second substrate <NUM>, and then transferred onto (or disposed on) the array module <NUM>, but not limited. In some embodiments, the quantity (number) of first alignment marks <NUM> may be greater than or equal to the quantity (number) of the second alignment marks <NUM>, but not limited. In some embodiments, the light-emitting module <NUM> may have four second alignment marks <NUM>, and the four second alignment marks <NUM> may respectively be disposed at four corners of the second substrate <NUM>, but not limited. In some embodiments, the quantity of the second alignment marks <NUM> in light-emitting module <NUM> is greater than (or less than) four, and the second alignment marks <NUM> may be disposed at other suitable position of the second substrate <NUM>. In some embodiments, the light-emitting module <NUM> has two second alignment marks <NUM>, and two second alignment marks <NUM> may respectively be disposed at two diagonal corners of the second substrate <NUM>. In some embodiments, the light-emitting module <NUM> may have at least one second alignment mark <NUM>. The quantity of the first alignment marks <NUM> or the position of the first alignment marks <NUM> may be correspond to the second alignment marks <NUM>, which can be adjusted according to the needs.

Refer to <FIG>, which are cross-sectional views of various stages of a process for manufacturing the display device. In some embodiments, the array module <NUM> includes a circuit layer <NUM>, and the circuit layer <NUM> is disposed on (or formed on) the first substrate <NUM>. Furthermore, the circuit layer <NUM> may include wires <NUM>, other conductive elements (not shown), other dielectric layers (not shown), but not limited. In some embodiments, the pads <NUM> may be disposed on (or electrically connected to) the circuit layer <NUM>. In some embodiments (shown in <FIG>), the first alignment mark <NUM> may be disposed on the circuit layer <NUM>. In some embodiments, the first alignment mark <NUM> may be disposed in (or formed in) the circuit layer <NUM> (not shown in <FIG>, for example, referring to <FIG>, the first alignment mark <NUM> is disposed in the circuit layer <NUM>). In some embodiments, the material of the first alignment mark <NUM> may be the same as or different from the pads <NUM>, the wires <NUM> or other conductive elements of the circuit layer <NUM>. In some embodiments, the first alignment mark <NUM> and the pads <NUM>, the wires <NUM> or other conductive elements of the circuit layer <NUM> may be formed in the same process or different process, but not limited. In some embodiment, the first alignment mark <NUM> may be formed before the process of forming the circuit layer <NUM>. In some embodiment, the first alignment mark <NUM> may be formed after the process of forming the pad <NUM>. In some embodiment, the material of the first alignment mark <NUM> may include opaque materials, shading materials, reflective materials or a combination of the above, but is not limited thereto. In some embodiment, the material of the first alignment mark <NUM> may include metal material, metal alloy, black photoresist or other suitable material, but is not limited thereto.

As shown in <FIG>, the light-emitting module <NUM> includes a plurality of pads <NUM> disposed on the light-emitting element <NUM>.

As shown in <FIG>, the distance D1 may be a distance between a center of the first alignment mark <NUM> and a center of the second alignment mark <NUM> along the X direction (or the Y direction). If the distance D1 is greater than the predetermined value, the position of the light-emitting module <NUM> will be fine-tuned.

As shown in <FIG>, the position of the light-emitting module <NUM> is fine-tuned. According to some embodiments, if the distance D1 is less than or equal to the predetermined value, the light-emitting module <NUM> is bonded onto the array module <NUM> as shown in <FIG>. After the bonding process, the second alignment mark <NUM> may approximately overlap with the first alignment mark <NUM> in Z direction, or the second alignment mark <NUM> may approximately aligned with the first alignment mark <NUM>.

As shown in <FIG>, after the light-emitting module <NUM> is disposed on (or bonded onto) the array module <NUM>, the second substrate <NUM> may be removed, but not limited. The light-emitting elements <NUM> and the pads <NUM> may be disposed on the array module <NUM>. In some embodiment, the pads <NUM> of the light-emitting module <NUM> may electrically connected to (or contact with) the corresponding pads <NUM> of the array module <NUM>. In some embodiment, the light-emitting element <NUM> may be electrically connected to the pad <NUM> through the pad <NUM>. According to some embodiments, if the distance D1 is less than or equal to the predetermined value, the production yield in mass producing the display device can increase.

Refer to <FIG>, which are top views of a first alignment mark and a second alignment mark in accordance with some embodiments. The profile of the first alignment marks and second alignment marks shown in <FIG> are merely examples, and the present disclosure is not limited thereto. In some embodiments, the first alignment mark 230A and the second alignment mark 330A are in different shapes. In some embodiments, the second alignment mark 330A may be adjacent to the first alignment mark 230A. In some embodiments, the second alignment mark 330A may enclose the first alignment mark 230A, as shown in <FIG>. In some embodiments, the second alignment mark may have an opening O, at least part of the opening O may overlap with the first alignment mark 230A in Z direction, but not limited. In some embodiments, at least part of the second alignment mark 330A may overlap with at least part of the first alignment mark 230A in Z direction. In some embodiments, the shape of the first alignment mark 230A and the shape of the second alignment mark 330A may include rectangle, circle, triangle, polygon, arc shape, obtuse angle shape, acute angle shape, round shape or other suitable shapes, but is not limited. In some embodiments, the shape of the first alignment mark 230A may be the same as or different from the shape of the second alignment mark 330A. In some embodiments, a distance dm between the second alignment mark 330A and the first alignment mark 230A in X direction (or Y direction) is greater than or equal to <NUM>, and less than or equal to the width W2 (shown in <FIG>). Distance dm may be defined as the minimum distance between the second alignment mark 330A and the first alignment mark 230A in X direction (or Y direction). In some embodiments, the position of the first alignment mark 230A and the position of the second alignment mark 330A can be exchanged.

In some embodiments, the second alignment mark 330B may have discontinuous parts, as shown in <FIG>. In some embodiments, the profile of the shape of the second alignment mark 330B is different from or the same as the shape of the first alignment mark 230B. The first alignment mark 230B may have a cross-shape, rectangular shape, polygonal shape, curved shape, circular shape, arc shape, obtuse angle shape, acute angle shape, round shape or other suitable shapes, but not limited. In some embodiments, the first alignment mark 230B may include protruding portions. The second alignment mark 330B may be adjacent to the first alignment mark 230B, and the second alignment mark 330B may have any shape correspond to (or in accordance with) the shape of the first alignment mark 230B, but not limited. For example, the second alignment mark 330B may have an L-shape (or other shape) and extend into the space between two adjacent protruding portions of the first alignment mark 230B, but not limited. The above "the second alignment mark 330B has any shape correspond to (or in accordance with) the shape of the first alignment mark 230B" includes that the second alignment mark 330B has any shape correspond to at least one side of the first alignment mark 230B. It should be noted that, one of the second alignment marks 330B may have discontinuous parts, these parts may correspond to one of the first alignment marks 230B, these parts can form a second alignment marks 330B, and these parts may have similar or different shapes. In some embodiments, the position of the first alignment mark 230B and the position of the second alignment mark 330B can be exchanged. In some embodiments, the shape of the first alignment mark 230B and the shape of the second alignment mark 330B may be complement each other.

Refer to <FIG>, which is a cross-sectional view of a display device 400A in accordance with some embodiments of the invention. The display device 400A includes an array module <NUM> and a light-emitting module <NUM>. The array module <NUM> includes a substrate <NUM>. The material of the substrate <NUM> may be the same as or similar to the material of the first substrate <NUM>. In some embodiments, some insulating layers <NUM>, <NUM>, <NUM>', <NUM> may be sequentially disposed on the substrate <NUM>. The insulating layers <NUM>, <NUM>, <NUM> may include, but are not limited to, silicon oxide, silicon nitride, silicon oxynitride or another suitable material.

A circuit layer <NUM> is disposed on the substrate <NUM>. The circuit layer <NUM> may include a plurality of transistors <NUM>. The transistor <NUM> may be a thin film transistor (TFT). For example, the transistor <NUM> may include a gate electrode <NUM>, a source/drain electrode <NUM>, and a semiconductor layer <NUM>. The gate electrode <NUM> may be disposed on the insulating layer <NUM> and the semiconductor layer <NUM>. The source/drain electrode <NUM> may be disposed on the semiconductor layer <NUM> and the doping layers <NUM>, and the semiconductor layer <NUM> may be disposed between the doping layers <NUM>. The material of the gate electrode <NUM> and the source/drain electrode <NUM> may include, but is not limited to, copper (Cu), aluminum (Al), molybdenum (Mo), gold (Au), chromium (Cr), nickel (Ni), titanium (Ti), other suitable material or alloy. The material of the semiconductor layer <NUM> may include, but is not limited to, amorphous silicon, polysilicon such as low-temp polysilicon (LTPS), metal oxide or other suitable materials. The metal oxide may include indium gallium zinc oxide (IGZO), indium zinc oxide (IZO), indium gallium zinc tin oxide (IGZTO) or other suitable material.

The array module <NUM> may include a plurality of wires <NUM> and includes a plurality of pads <NUM>. The pads <NUM> are disposed on the circuit layer <NUM>. According to some embodiments, the pads <NUM> may be disposed on the insulating layer <NUM> and the wires <NUM>. The transistor <NUM> may be electrically connected to the pad <NUM> through the wire <NUM>, but not limited. The material of the wire <NUM> and the pad <NUM> may be the same as or different from the material of the source/drain electrode <NUM>.

In some embodiments, the first alignment mark <NUM> may be disposed on the insulating layer <NUM>. In some embodiments, the first alignment mark <NUM> and the gate electrode <NUM> may be formed in the same process. In some embodiments, the material of the first alignment mark <NUM> and the material of the gate electrode <NUM> may be same. In some embodiments, the first alignment mark <NUM> may include metal material that is disposed in the insulating layer <NUM>. In other embodiments, the first alignment mark <NUM> and the pad <NUM> may be formed in the same process. In some embodiments, the material of the first alignment mark <NUM> and the material of the gate electrode <NUM> may be same. In other embodiments, the material of the first alignment mark <NUM> and the material of source/drain electrode <NUM> may be same.

As shown in <FIG>, the light-emitting module <NUM> includes a substrate <NUM>. The substrate <NUM> may include a glass substrate, a ceramic substrate, a plastic substrate or another suitable substrate, but not limited. The material of the substrate <NUM> may include sapphire, Si, SiC, other suitable materials or combinations thereof, but are not limited thereto. In some embodiments, the light-emitting module <NUM> may include insulating layers <NUM>, <NUM>, <NUM>, and the insulating layers <NUM>, <NUM>, <NUM> are disposed on the substrate <NUM>. The insulating layers <NUM>, <NUM>, <NUM> may include, but are not limited to, silicon oxide, silicon nitride, silicon oxynitride or another suitable material. The light-emitting module <NUM> may include a plurality of the transistors <NUM>. For example, the transistor <NUM> may include a gate electrode <NUM>, a source/drain electrode <NUM>, and a semiconductor layer <NUM>. The gate electrode <NUM> may be disposed on the insulating layer <NUM>. The materials of the gate electrode <NUM>, the source/drain electrode <NUM> and the semiconductor layer <NUM> may be the same as, similar to or different from those of the gate electrode <NUM>, the source/drain electrode <NUM> and the semiconductor layer <NUM>, respectively. The light-emitting module <NUM> includes a plurality of wires <NUM> and pads <NUM>. In some embodiments, the transistor <NUM> may be electrically connected to the pad <NUM> through the wire <NUM>. In some embodiments, the transistor <NUM> may be electrically connected to the transistor <NUM>. In some embodiments, the pad <NUM> may be electrically connected to (or contact with) the pad <NUM>. In some embodiments, the transistor <NUM> may use as a driving transistor. In some embodiments, the transistor <NUM> may use as a switch transistor. In some embodiments, more transistors (or elements) may be disposed on the substrate <NUM> or the substrate <NUM>, such as reset transistor or capacitor, but not limited. In some embodiments, the transistor <NUM> and the transistor <NUM> may disposed on the same substrate (such as substrate <NUM> or the substrate <NUM>). The structure of the transistor <NUM> (or the transistor <NUM>) described above is an example, and the disclosure is not limited thereto. In some embodiments, the transistor <NUM> (or the transistor <NUM>) can be top gate thin film transistor, bottom gate thin film transistor, double gate thin film transistor, but not limited. In addition, the transistor <NUM> (or the transistor <NUM>) can include amorphous silicon (a-Si:H) transistor, low temperature poly-silicon (LTPS) transistor, indium gallium zinc oxide transistor (IGZO) or other suitable transistor, but not limited. The light-emitting element <NUM> may be electrically connected to the transistor <NUM> and the transistor <NUM> through the conductive elements which are disposed in the array module <NUM> or the light-emitting module <NUM>. According to some embodiments, at least one of the light-emitting elements <NUM> are electrically connected to at least one of the pads <NUM> in the array module <NUM>.

As shown in <FIG>, the light-emitting module <NUM> includes insulating layer <NUM> and insulating layer <NUM>. The light-emitting module <NUM> includes a plurality of light-emitting elements <NUM> and pads <NUM>. In some embodiments, the light-emitting element <NUM> and the pad <NUM> may be surrounded by the insulating layer <NUM> and the insulating layer <NUM>, but not limited. The insulating layer <NUM> and the insulating layer <NUM> may be disposed to protect the light-emitting element <NUM> or the pad <NUM> from damage or pollution (such as water or air), but not limited. The material of the insulating layer <NUM> (or the insulating layer <NUM>) may include, but is not limited to, resin or another suitable material. The light-emitting element <NUM> and the pad <NUM> may be the same as or similar to the light-emitting element <NUM> and the pad <NUM> shown in <FIG>, respectively. In some embodiments, the order of the above layers or elements can be changed or replaced as needed. In some embodiments, the above layers can be replaced or removed as needed.

As shown in <FIG>, the light-emitting module <NUM> includes a light blocking layer <NUM>. The light blocking layer <NUM> may be disposed on the light-emitting element <NUM>. The light blocking layer <NUM> has a plurality of openings B-O, the openings B-O may overlap with the light-emitting element <NUM> in Z direction. In some embodiments, the light blocking layer <NUM> does not overlap with the light-emitting element <NUM> in Z direction. The light-emitting module <NUM> may include a plurality of light conversion layer <NUM>. The light conversion layer <NUM> may be disposed on (or cover) the light-emitting element <NUM>. In some embodiments, the light conversion layer <NUM> may be adjacent to the light-emitting element <NUM>. The material of the light conversion layer <NUM> may include, but is not limited to, quantum dot, fluorescent material, phosphorescent material or another conversion material. For example, the light conversion layer <NUM> may be an organic or an inorganic layer blended with a quantum dot. The quantum dot may include, but is not limited to, zinc, cadmium, selenium, sulfur, InP, GaSb, GaAs, CdSe, CdS, ZnS or a combination thereof.

The light-emitting module <NUM> further includes a protective layer <NUM> and a color filter layer <NUM>. The light-emitting element <NUM> may be disposed between the protective layer <NUM> and the substrate <NUM>. The color filter layer <NUM> may be disposed between the light conversion layer <NUM> and the protective layer <NUM>, but not limited. The protective layer <NUM> may be single layer structure, multilayer structure, composite structure, but not limited. The material of the protective layer <NUM> may include organic material, inorganic material, or a combination thereof. In some embodiments, the material of the protective layer <NUM> may be a transparent substrate. In some embodiments, the material of the protective layer <NUM> may include phosphosilicate glass (PSG), borophosphosilicate glass (BPSG), silicon oxide, silicon nitride, or silicon oxynitride, but not limited. In some embodiments, the color filter layer <NUM> may be disposed on at least one of the light conversion layer <NUM>. In some embodiments, the color filter layer <NUM> may be respectively disposed on the corresponding light conversion layer <NUM>. In some embodiments, the color filter layer <NUM> may overlap with at least part of the light blocking layer <NUM> in Z direction in order to reduce light leakage. In some embodiments (not shown), the color filter layer <NUM> may disposed between the light conversion layer <NUM> and the light-emitting element <NUM>.

In some embodiments, the second alignment mark <NUM> may be disposed in (or formed in) the second substrate <NUM>. According to the invention (<FIG>), the second substrate <NUM> may be a transparent substrate or non-transparent substrate, a through hole TH penetrates the second substrate <NUM>, and the through hole TH is the second alignment mark <NUM>. In some embodiments, the through hole TH may penetrate at least part of the layers (or the elements) formed on the substrate <NUM>. For example (shown as <FIG>), the through hole TH may penetrate the substrate <NUM>, the insulating layers <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, the light blocking layer <NUM> and the protective layer <NUM>, but not limited. In some embodiments, in Z direction, a shape of the through hole TH may include rectangle, circle, triangle, polygon, arc shape, obtuse angle shape, acute angle shape, round shape or other suitable shapes, but not limited. In some embodiments, in the direction of the cross section, the through hole has an inverted trapezoid profile, rectangular profile or other shape profile, but not limited. However, the scope of the disclosure is not limiting.

As shown in <FIG>, the second alignment mark <NUM> approximately overlaps with (or aligned with) the first alignment mark <NUM> in Z direction. The second alignment mark <NUM> (such as through hole TH) have a bottom surface BS and top surface TS opposite to the bottom surface BS, and the bottom surface BS is near to the array module <NUM>. In the cross section, the bottom surface BS of the second alignment mark <NUM> (such as through hole TH) may have a length L1, and the top surface TS of the second alignment mark <NUM> may have length L3. In some embodiments, the length L3 may be greater than or equal to the length L1. In some embodiments, the length L3 may be less than or equal to the length L1. In some embodiments, the length L3 also may be defined as the maximum length of the top surface TS of the second alignment mark <NUM> in top view, and length L1 also may be defined as the maximum length of the bottom surface BS of the second alignment mark <NUM> in top view.

As shown in <FIG>, in the cross section, the first alignment mark <NUM> has a length L2. In some embodiments, the length L1 is greater than or equal to the length L2. The length L1 is greater than the length L2 so that the CCD camera could receive both images of the first alignment mark <NUM> and the second alignment mark <NUM>. In addition, there is an angle θ constituted by an extension direction of the side surface of the second alignment mark <NUM> (such as through hole TH) and an extension direction of the bottom surface BS of the second alignment mark <NUM>. In some embodiments, the angle θ is in a range from about <NUM>° to about <NUM>°. In some embodiments, the angle θ is in a range from about <NUM>° to about <NUM>°. In some embodiments, the side surface of the second alignment mark <NUM> (such as through hole TH) is a curved edge or an irregular edge. For example, in the Z direction, viewers can see the elements (such as first alignment mark <NUM> or other layers (or elements) of the array module <NUM>) through the second alignment mark <NUM> (through hole TH).

As shown in <FIG>, at least one spacer <NUM> may be disposed between the array module <NUM> and the light-emitting module <NUM>. The spacer <NUM> may include resin or other suitable materials, but not limited. In some embodiments, at least one space <NUM> may be formed between the array module <NUM> and the light-emitting module <NUM> by the spacer <NUM>. The space <NUM> may include air, transparent material or other suitable materials, but not limited.

Refer to <FIG>, which illustrates a cross-sectional view of a display device 400B in accordance with some embodiments of the invention. In some embodiments, one of the differences between the display device 400B and the display device 400A is that a second alignment mark <NUM> of the display device 400B may include a filling materials FM, the filling materials FM may be disposed in (or filled in) the through hole TH, and the through hole TH with the filling materials FM may be regarded as the second alignment mark <NUM>. In some embodiments, the filling materials may include transparent material. The filling materials FM may include, but is not limited to, silicon oxide, silicon nitride, silicon oxynitride or another suitable material.

Refer to <FIG>, which illustrates a cross-sectional view of a display device 400C in accordance with some embodiments. In some embodiments, one of the differences between the display device 400C and the display device 400A is that a notch <NUM> may penetrate part of layers (or elements) in the light-emitting module <NUM>. In some embodiments (<FIG>), the notch <NUM> may penetrate the insulating layers <NUM>, <NUM>, the light blocking layer <NUM> and the protective layer <NUM>. The display device 400C may include a second alignment mark <NUM>. The material of the second alignment mark <NUM> may be the same as or similar to the material of the gate electrode <NUM> of the transistor <NUM>, but not limited. In some embodiments, the second alignment mark <NUM> and a portion of the transistor <NUM> (such as source/drain electrode <NUM>) may be formed in the same process or different process. In some embodiments, the material of the second alignment mark <NUM> may be the same as or different from the material of a portion of the transistor <NUM> (such as source/drain electrode <NUM>).

As shown in <FIG>, the notch <NUM> has a bottom surface BS', and the bottom surface BS' is near to the array module <NUM>. In the cross section, the bottom surface BS' of the notch <NUM> may have a length L1'. In some embodiments, the length L1' may be defined as the maximum length of the bottom surface BS' of the notch <NUM> in top view. As shown in <FIG>, the second alignment mark <NUM> has length L4, the length L4 may be defined as the maximum length of the second alignment mark <NUM> in X direction (or Y direction). In some embodiments, the length L4 is less than or equal to the length L1'. In some embodiments, at least part of the second alignment mark <NUM> may overlap with the first alignment mark <NUM> in Z direction. In some embodiments, at least part of the second alignment mark <NUM> may be aligned with the first alignment mark <NUM>. In some embodiments, the shape of the notch <NUM> may be the same as or different from of shape of the second alignment mark <NUM> in Z direction.

Refer to <FIG>, which illustrates a cross-sectional view of a display device 400D in accordance with some embodiments of the invention. In some embodiments, one of the differences between the display device 400D and the display device 400A is that the array module <NUM> of the display device 400D may include a spacer <NUM> and a protruding portion <NUM> that is disposed on the spacer <NUM>. The protruding portion <NUM> may be regarded as the first alignment mark of the array module <NUM>. Moreover, the profile of a second alignment mark <NUM> of the light-emitting module <NUM> may be correspond to (or accordance with) the profile of the protruding portion <NUM>. The protruding portion <NUM> may protrude into the second alignment mark <NUM> of the light-emitting module <NUM>. In addition, the display device <NUM> may include a plurality of solders <NUM> that are electrically connected to the pads <NUM> and the pads <NUM>. In addition, at least one space <NUM> may be formed between the array module <NUM> and the light-emitting module <NUM> by the spacer <NUM>. The space <NUM> may include air, a transparent material, or other suitable materials, but the disclosure is not limited thereto.

As shown in <FIG>, a display device <NUM> may include two or more light-emitting modules with different arrangements. As shown in <FIG>, the display device <NUM> may include an active region <NUM> and a peripheral region <NUM> that is adjacent to (or surrounds) the active region <NUM>. The display device <NUM> may include a plurality of second alignment marks 830A and 830B on the peripheral region <NUM> and the active region <NUM>. For example, the second alignment marks 830A are located on the peripheral region <NUM>, and the second alignment marks 830B are located on the active region <NUM>. As shown in <FIG>, a light-emitting module 800A may have a second substrate <NUM>, light-emitting elements <NUM> and second alignment marks 830A. As shown in <FIG>, a light-emitting module 800B may have a second substrate <NUM>, light-emitting elements <NUM> and second alignment marks 830B. One of the differences between the light-emitting module 800A and the light-emitting module 800B is the arrangement of the light-emitting elements <NUM>. As shown in <FIG>, the display device <NUM> may include a plurality of second alignment marks 830A of the light-emitting module 800A and a plurality of second alignment marks 830B of the light-emitting module 800B. The arrangement of the light-emitting module 800A and the light-emitting module 800B may be adjusted according to the active region <NUM> and the peripheral region <NUM>. For example, the second alignment mark 830A may be disposed on the active region <NUM> and the peripheral region <NUM>. The second alignment mark 830B may be disposed on the active region <NUM>.

Claim 1:
A method for manufacturing a display device, comprising:
providing an array module (<NUM>) having at least one first alignment mark (<NUM>) and a first substrate (<NUM>);
providing a light-emitting module (<NUM>) having at least one second alignment mark (<NUM>) and a second substrate (<NUM>);
aligning the light-emitting module (<NUM>) and the array module (<NUM>) by the at least one first alignment mark (<NUM>) and the at least one second alignment mark (<NUM>) , wherein aligning the light-emitting module (<NUM>) and the array module (<NUM>) comprises approaching the at least one second alignment mark (<NUM>) and the at least one first alignment mark (<NUM>) into a detecting region (S), and after approaching the at least one second alignment mark with the at least one first alignment mark into the detecting region, detecting a distance (X1, Y1) between the at least one second alignment mark (<NUM>) and the at least one first alignment mark (<NUM>), and then comparing the distance with a predetermined value; wherein
the display device comprises a plurality of pixels (P), and the predetermined value is less than or equal to half of a pixel pitch (W3) of the plurality of pixels (P); and
bonding the light-emitting module (<NUM>) onto the array module (<NUM>); wherein
the at least one second alignment mark (<NUM>) is a through hole (TH) and penetrates the second substrate (<NUM>),
an angle (θ) between an extension direction of a side surface of the at least one second alignment mark (<NUM>) and an extension direction of a bottom surface (BS) of the at least one second alignment mark (<NUM>) is greater than or equal to <NUM> degrees and smaller than <NUM> degrees.