Display panel and manufacturing method thereof

Abstract

The invention provides a display panel and a manufacturing method thereof. The display panel comprises a circuit substrate, a patterned structure layer, a plurality of micro light-emitting chips, a plurality of refractive spheres and a filling layer. A plurality of pixel areas are defined on the circuit substrate, the patterned structure layer is arranged on the circuit substrate to partition the pixel areas, and a plurality of containing spaces corresponding to the pixel areas respectively are formed. The miniature light-emitting chips are connected with the circuit substrate and are respectively arranged in the accommodating spaces corresponding to the pixel areas. The dioptric balls are arranged on the sides, away from the circuit substrate, of the miniature light-emitting chips, and each dioptric ball is contained in one of the containing spaces. In a direction parallel to the surface of the circuit substrate, the filling layer is filled between the patterned structure layer and each refractive sphere.

Description

Technical Field

[0001] This invention relates to an optoelectronic component and its manufacturing method, and more particularly to a display panel and its manufacturing method. Background Technology

[0002] In display panels that use light-emitting chips as pixels, existing panel packaging using light-reflective banks can reduce light crosstalk between pixels and collect large-angle divergent light from the light-emitting chips to some extent, but it still has shortcomings. For example, although a light-reflective bank can collect divergent light through reflection, it does not have the ability to converge light itself, and its effect on improving front light output is only indirect and very limited.

[0003] In recent years, the idea of ​​creating microlenses within display panels to actively converge light has been proposed. These microlenses are created by reflowing patterned photoresist, converging it into a lens shape. However, this method still has some limitations and drawbacks. These limitations include the need for a flat surface to easily control the shape of the photoresist after reflow, thus requiring a planarization layer to be first applied to the chip. This results in the microlens facing the chip also being flat after forming, meaning the reflow creates a plano-convex lens; therefore, light only converges once when passing through the microlens, performing worse than a spherical lens or biconvex lens. Due to insufficient deflection and material refractive index limitations, the patterned area must significantly extend beyond the chip to achieve a visible light-gathering effect, which is unfavorable for high-pixel-density displays. Furthermore, since each sub-pixel requires individual photoresist injection for the reflow process, it is not only inefficient but also difficult to control the lens's dimensional uniformity. Moreover, the reflow process needs to be adjusted for different chip sizes, but optimization involves many variables and high experimental costs. In addition, although the total amount of light from the front of the display panel formed by this packaging process is increased, this light is actually distributed across the entire lens, so the visual brightness is not significantly improved. Summary of the Invention

[0004] This invention relates to a display panel in which each pixel area is equipped with a refractive sphere to enhance the efficiency of light convergence, thereby significantly improving the brightness of the display panel. Furthermore, because the area occupied by the refractive sphere is greatly reduced, this invention is applicable to display panels with high requirements for both brightness and pixel density (e.g., wearable displays).

[0005] This invention relates to a method for manufacturing a display panel that replaces the aforementioned step of forming a lens using a reflow process by inserting a sphere, thereby enabling rapid completion of lens fabrication and encapsulation for the display panel. Furthermore, this manufacturing method has fewer prerequisites or limitations and lower optimization design costs.

[0006] One embodiment of the present invention provides a display panel including a circuit substrate, a patterned structure layer, a plurality of micro-light-emitting chips, a plurality of refractive spheres, and a filling layer. The circuit substrate defines a plurality of pixel regions. The patterned structure layer is disposed on the circuit substrate to separate these pixel regions and forms a plurality of accommodating spaces corresponding to these pixel regions. The micro-light-emitting chips are connected to the circuit substrate and are respectively disposed in these accommodating spaces corresponding to these pixel regions. The refractive spheres are disposed on the side of the micro-light-emitting chips away from the circuit substrate, and each refractive sphere is respectively accommodated in one of the accommodating spaces. Each refractive sphere has a spherical surface, and the spherical surface is at a distance from the micro-light-emitting chip on the side facing the corresponding micro-light-emitting chip, with the distance increasing from the center of the spherical surface towards the edge of the spherical surface. In a direction parallel to the surface of the circuit substrate, the filling layer fills the space between the patterned structure layer and each refractive sphere, and the materials of the filling layer, the patterned structure layer, and the refractive spheres are all different.

[0007] An embodiment of the present invention provides a method for manufacturing a display panel, comprising: providing a plurality of refractive spheres having different sizes; providing a first screening unit and a second screening unit, the first screening unit having a first screening size and the second screening unit having a second screening size greater than or equal to the first screening size; placing the refractive spheres into the first screening unit to obtain a portion of the refractive spheres having a first screening size or larger; providing a carrier plate and combining the second screening unit with the carrier plate such that the second screening unit forms a plurality of receiving spaces on the carrier plate; and placing the refractive spheres having a first screening size or larger into the second screening unit, such that the refractive spheres enter the receiving spaces via the second screening unit.

[0008] In the display panel and manufacturing method of the embodiments of the present invention, since a refractive sphere is used as a lens, it is helpful to quickly complete the lens fabrication of the entire display panel, without the need for photoresist reflow lenses and pre-planarization layer processes. Furthermore, for light from the micro-light-emitting chip, the refractive sphere can provide a secondary refraction converging effect, effectively improving the brightness of the display panel while significantly reducing the area occupied by the refractive sphere, thus balancing the brightness and size requirements of the micro-display. In addition, compared to the reflow process, which may be limited or complex due to differences in pixel area size, the embodiments of the present invention only require changing the size of the refractive sphere and the position of the accommodating space to quickly adjust the design, resulting in lower optimization design costs. Attached Figure Description

[0009] Figure 1 This is a partial cross-sectional schematic diagram of a display panel according to an embodiment of the present invention;

[0010] Figure 2This is a partial cross-sectional schematic diagram of a display panel according to another embodiment of the present invention;

[0011] Figure 3 This is a partial cross-sectional schematic diagram of a display panel according to another embodiment of the present invention;

[0012] Figure 4 This is a perspective view of the patterned structure layer and the refractive sphere in a display panel according to another embodiment of the present invention;

[0013] Figure 5 This is a schematic diagram illustrating the relative positional relationship between the refractive sphere and the micro-light-emitting chip in a display panel according to another embodiment of the present invention.

[0014] Figure 6 This is a partial cross-sectional schematic diagram of a display panel according to another embodiment of the present invention;

[0015] Figure 7 This is a partial cross-sectional schematic diagram of a display panel according to another embodiment of the present invention;

[0016] Figures 8A to 8I This is a schematic diagram illustrating the process of manufacturing a display panel according to an embodiment of the present invention;

[0017] Figure 9 This is a cross-sectional schematic diagram illustrating one step of a method for manufacturing a display panel according to another embodiment of the present invention;

[0018] Figure 10A A perspective view illustrating the relative relationship between the refractive sphere, patterned structure layer, and accommodating space of a display panel according to another embodiment of the present invention;

[0019] Figure 10B To show Figure 10A A top view schematic diagram showing the relative relationship between the micro-light-emitting chips in the display panel and the accommodating space;

[0020] Figure 11A A perspective view illustrating the relative relationship between the refractive sphere, patterned structure layer, and accommodating space of a display panel according to another embodiment of the present invention;

[0021] Figure 11B To show Figure 11A A top view schematic diagram showing the relative relationship between the micro-light-emitting chips in the display panel and the accommodating space;

[0022] Figures 12A to 12E It shows Figure 8F Various possible variations of the steps;

[0023] Figures 13A to 13C It shows Figure 8H Various possible variations of the steps are described. Detailed Implementation

[0024] Reference will now be made in detail to exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same element references are used in the drawings and description to denote the same or similar parts.

[0025] Figure 1 This is a partial cross-sectional schematic diagram of a display panel according to an embodiment of the present invention. Please refer to... Figure 1 The display panel 100 of this embodiment includes a circuit board 110, a patterned structure layer 120, a plurality of micro-light-emitting chips 130, a plurality of refractive spheres 140, and a filling layer 150. The circuit board 110 defines a plurality of pixel regions A1. The patterned structure layer 120 is disposed on the circuit board 110 to separate these pixel regions A1 and forms a plurality of accommodating spaces C1 corresponding to these pixel regions A1. The micro-light-emitting chips 130 are electrically connected to the circuit board 110 and are respectively disposed in the accommodating spaces C1 corresponding to these pixel regions A1. In this embodiment, these micro-light-emitting chips 130 are, for example, micro-light-emitting diodes. These refractive spheres 140 are disposed on the side of the micro-light-emitting chips 130 away from the circuit board 110, and each refractive sphere 140 is respectively housed in one of the accommodating spaces C1. Each refractive sphere 140 has a spherical surface 142, and the spherical surface 142 is at a distance D1 from the micro-light-emitting chip 130 on the side facing the corresponding micro-light-emitting chip 130, and the distance D1 increases from the center of the spherical surface 142 towards the edge of the spherical surface 142. In another embodiment, as... Figure 2 As shown, each refractive sphere 140 directly contacts the corresponding micro-light-emitting chip 130, that is, the distance D1 between the sphere 142 and the micro-light-emitting chip 130 at the center of the sphere 142 is 0. In this embodiment, in a direction parallel to the surface 112 of the circuit board 110, a filling layer 150 fills the space between the patterned structure layer 120 and each refractive sphere 140, and the materials of the filling layer 150, the patterned structure layer 120, and the refractive spheres 140 are all different and have different refractive indices.

[0026] In this embodiment, in a direction perpendicular to the surface 112 of the circuit substrate 110, the filling layer 150 at least fills the space between each refractive sphere 140 and the corresponding micro-light-emitting chip 130. Figure 1For example, the filling layer 150 further covers and encloses the refractive sphere 140. In this embodiment, the filling layer 150 is a light-transmitting material, such as transparent resin, and is disposed at least on the side of each spherical surface 142 away from the corresponding micro-light-emitting chip 130, for example, covering more than half the height of the refractive sphere 140. The patterned structure layer 120 is a light-reflecting layer or a light-absorbing layer. For example, a reflective material such as silver (Ag) or aluminum (Al) can be deposited on the surface of the patterned structure layer 120, or a dark molding compound or a light-absorbing material such as carbon black can be added to the photoresist to give the patterned structure layer 120 a light-absorbing effect.

[0027] In this embodiment, the display panel 100 further includes an optical adhesive layer 170, which covers the patterned structure layer 120, the filler layer 150, and the refractive sphere 140. The display panel 100 also includes a light-transmitting substrate 160 disposed on the side of the micro-light-emitting chips 130 away from the circuit board 110 and positioned on the optical adhesive layer 170. In this embodiment, the refractive index of the filler layer 150 is less than the refractive index of the optical adhesive layer 170. In one embodiment, the refractive index of the refractive sphere 140 is between 1.7 and 2, for example, 1.9; the refractive indices of the optical adhesive layer 170 and the light-transmitting substrate 160 are, for example, 1.5; and the refractive index of the filler layer 150 is, for example, 1.3.

[0028] For light from the micro light-emitting chip 130, the refractive sphere 140, having upper and lower refractive surfaces, can provide a converging effect with secondary deflection. While effectively improving the brightness of the display panel 100, the area occupied by the refractive sphere 140 is greatly reduced, thus balancing the high brightness and small size requirements of the display panel 100.

[0029] Figure 3 This is a partial cross-sectional schematic diagram of a display panel according to another embodiment of the present invention. Please refer to... Figure 3 The display panel 100a in this embodiment and Figure 1 The display panel 100a is similar to that of the circuit board 110, but the main differences are as follows. In the display panel 100a of this embodiment, a light-transmitting substrate 160 is disposed on the side of the micro-light-emitting chips 130 away from the circuit board 110, and a patterned structure layer 120 is connected to the light-transmitting substrate 160. Furthermore, in this embodiment, an optical adhesive layer 170 is disposed between the patterned structure layer 120 and the micro-light-emitting chips 130. Moreover, in this embodiment, the display panel 100a also includes a planarization layer 180 covering the micro-light-emitting chips 130, and the planarization layer 180 is disposed between the optical adhesive layer 170 and the circuit board 110.

[0030] In this embodiment, each refractive sphere 140 is in direct contact with the light-transmitting substrate 160. Furthermore, in a direction perpendicular to the surface 112 of the circuit board 110, a filling layer 150 is filled between each refractive sphere 140 and the light-transmitting substrate 160.

[0031] The manufacturing method of the display panel 100a includes providing a light-transmitting substrate 160 and a circuit substrate 110, and forming a patterned structure layer 120 on the light-transmitting substrate 160. Then, after the refractive spheres 140 enter the accommodating spaces C1, the refractive spheres 140 are sealed between the light-transmitting substrate 160 and the circuit substrate 110. Specifically, a plurality of micro-light-emitting chips 130 may be provided on the circuit substrate 110, and then a planarization layer 180 may be used to cover these micro-light-emitting chips 130. Next, an optical adhesive layer 170 is coated on the planarization layer 180, and then the light-transmitting substrate 160 is flipped so that the patterned structure layer 120 and the refractive spheres 140 are bonded to the optical adhesive layer 170, thereby achieving the effect of sealing the refractive spheres 140 between the light-transmitting substrate 160 and the circuit substrate 110.

[0032] Figure 4 This is a perspective view of the patterned structure layer and the refractive sphere in a display panel according to another embodiment of the present invention. Please refer to... Figure 4 In this embodiment, the patterned structure layer 120 conformally surrounds these refractive spheres 140 from a viewing angle perpendicular to the surface 112 of the circuit board 110. Figure 4 In order to clearly show the relationship between the patterned structure layer 120, the micro light-emitting chip 130 and the refractive sphere 140, the refractive sphere 140 located in the central accommodating space C1 is not shown here.

[0033] Figure 5 This is a schematic diagram illustrating the relative positional relationship between the refractive sphere and the micro-light-emitting chip in a display panel according to another embodiment of the present invention. Please refer to... Figure 5Each of these micro-light-emitting chips 130 has a light-emitting layer 132 parallel to the circuit substrate 110. In a direction parallel to the surface 112 of the circuit substrate 110, at least a portion of the geometric center G1 of the light-emitting layer 132 has a first offset S1 relative to the geometric center G2 of the micro-light-emitting chip 130, and a second offset S2 relative to the geometric center G3 of the accommodating space C1, wherein the first offset S1 is greater than the second offset S2, and the second offset S2 is preferably 0. Specifically, in, for example, lateral chips or flip chips, a portion of the light-emitting layer 132 may be removed due to process factors, causing the geometric center G1 and geometric center G2 to not coincide. In this embodiment, the position of the geometric center G3 of the accommodating space C1 can be controlled by adjusting the exposure area of ​​the patterned structure layer 120. In this way, the center of the refractive sphere 140 can be aligned as closely as possible with the geometric center G1 of the light-emitting layer 132, thereby maximizing the light extraction efficiency.

[0034] Figure 6 This is a partial cross-sectional schematic diagram of a display panel according to another embodiment of the present invention. Please refer to... Figure 6 The display panel 100b in this embodiment and Figure 1 The display panel is similar to 100, but the main differences between the two are described below. Figure 1 In the display panel 100, the circuit board 110 is an opaque substrate, while in the display panel 100b of this embodiment, the circuit board 110b is a transparent substrate, thus making the display panel 100b a transparent display panel.

[0035] Figure 7 This is a partial cross-sectional schematic diagram of a display panel according to another embodiment of the present invention. Please refer to... Figure 7 The display panel 100c in this embodiment and Figure 3 The display panel is similar to the 100a, but the main differences between the two are described below. Figure 3 In the display panel 100a, the circuit board 110 is an opaque substrate, while in the display panel 100c of this embodiment, the circuit board 110b is a transparent substrate, thus making the display panel 100c a transparent display panel.

[0036] Figure 6 and Figure 7 Compared to the example Figure 1 and Figure 3 The main difference is that, Figure 6 and Figure 7 The circuit board 110b used in this embodiment is suitable for use in transparent displays. To further improve the light transmittance of display panels 100b and 100c, the patterned structure layer 120 is a light-transmitting layer. Figure 6 and Figure 7In one embodiment, the patterned structure layer 120 is, for example, a light-transmitting material, and the refractive index of the filling layer 150 is less than that of the patterned structure layer 120.

[0037] Figures 8A to 8I This is a schematic diagram illustrating a process for manufacturing a display panel according to an embodiment of the present invention, wherein... Figures 8A to 8C , Figure 8E and Figure 8F This is a 3D schematic diagram. Figure 8D This is a cross-sectional schematic diagram, and Figures 8G to 8I This is a top-view diagram. Please refer to it. Figures 8A to 8I The manufacturing method of the display panel in this embodiment can be used to manufacture the display panels of the above embodiments, and the following description will take the manufacture of the above display panel 100 as an example. The manufacturing method of the display panel in this embodiment includes the following steps. First, as Figure 8A As shown, a plurality of refractive spheres 140 are provided, which have different sizes, such as different diameters. In this embodiment, the diameter of the refractive spheres 140 is, for example, in the range of 30 micrometers to 50 micrometers. Furthermore, a first screening unit 210 and a second screening unit 220 (e.g., ...) are provided. Figure 8D and Figure 8E As shown), the first screening unit 210 has a first screening size W1, and the second screening unit 220 has a second screening size W2 that is greater than or equal to the first screening size W1, wherein the first screening size W1 and the second screening size W2 are, for example, the width of the hole. Then, as... Figure 8B As shown, these refractive spheres 140 are inserted into the first screening unit 210 to obtain a portion of refractive spheres 140 having a first screening size W1 or larger. In this embodiment, the first screening size W1 is, for example, 38 micrometers. Figure 8B The process yields refractive spheres 140 with a diameter greater than 38 micrometers, while refractive spheres 140 with a diameter less than 38 micrometers pass through the aperture H1 of the first screening unit 210 and fall into the chassis 230. For example... Figure 8C As shown, after Figure 8BAfter the steps, refractive spheres 140 with a diameter greater than 38 micrometers cannot pass through the aperture of the first screening size W1 and remain in the first screening unit 210. The manufacturing method of the display panel in this embodiment further includes providing an oscillation unit 240, and activating the oscillation unit 240 when these refractive spheres 140 are placed into the first screening unit 210, causing the oscillation unit 240 to act on the first screening unit 210. The oscillation unit 240 is, for example, an ultrasonic vibration clamp, with an oscillation frequency of, for example, 10 to 2000 Hz. When activated, it can drive the first screening unit 210 to vibrate, thus helping to eliminate the effects of static electricity or friction, allowing refractive spheres 140 with a diameter less than 38 micrometers to smoothly pass through the aperture H1 of the first screening unit 210 and fall into the chassis 230.

[0038] On the other hand, such as Figure 8D As shown, a carrier plate 250 is provided, and the second screening unit 220 is combined with the carrier plate 250 so that the second screening unit 220 forms a plurality of accommodating spaces C1 on the carrier plate 250. That is, since the patterned structure layer 120 is formed by a patterning process, the aperture of these accommodating spaces C1 can accurately and consistently conform to the second screening size W2. Therefore, in this embodiment, the second screening unit 220 can directly utilize... Figure 1 The patterned structural layer 120 is used instead. Specifically, the carrier plate 250 is, for example, a patterned structural layer 120. Figure 1 The circuit substrate 110, after being coated with a patternable photoresist material on the carrier 250, is then patterned using a second screening size W2 to form a patterned structure layer 120 with the second screening size W2. In this embodiment, the circuit substrate 110 has a plurality of pixel regions A1 corresponding to these accommodating spaces C1, each pixel region A1 having at least one micro-light-emitting chip 130, and the second screening unit 220 exposes these micro-light-emitting chips 130 through a patterning process.

[0039] After that, as Figure 8E and Figure 8F Refractive spheres 140 with a first screening size W1 or greater are placed into the second screening unit 220, allowing them to enter the receiving spaces C1 via the second screening unit 220. Continuing from the previous description, the second screening size W2 is 38 micrometers or greater (e.g., 42 micrometers). When refractive spheres 140 with a diameter of 38 micrometers or greater are placed on the second screening unit 220, the oscillation unit 240 is activated, causing it to act on the second screening unit 220. In this way, only refractive spheres 140 with a diameter between 38 and 42 micrometers will enter the receiving space C1. And if... Figure 8G Some of the refractive spheres 140 that did not enter or could not enter the accommodating space C1 remain on the second screening unit 220. Figure 8HIn this step, the refractive sphere 140 that remains on the second screening unit 220 but has not entered or cannot enter the accommodating space C1 can be removed. Finally, as Figure 8I As shown, the step of placing the refractive sphere 140 into the accommodating space C1 has been completed.

[0040] Please refer to again Figure 8E and Figure 8F The manufacturing method of the display panel in this embodiment may further include the following steps. First, as... Figure 8E As shown, a third filtering unit 260 is provided, which has a third filtering size W3 that is larger than the second filtering size W2. Then, as... Figure 8F As shown, the second screening unit 220 and the carrier plate 250 are placed into the third screening unit 260. Furthermore, a recovery unit 270 is provided and positioned to one side of the third screening unit 260 to recover the refractive spheres 140 that have not entered these pixel regions A1. For example, in this embodiment, the third screening size W3 is, for example, 100 micrometers, which is, for example, the width of the aperture H3 of the third screening unit 260. This size is suitable for allowing all refractive spheres 140 that have not entered pixel regions A1 to pass through and be recovered by the recovery unit 270, which is, for example, a recovery basin. When the oscillation unit 240 is activated, it can cause the third screening unit 260 to vibrate, thereby causing the second screening unit 220 to vibrate, so that refractive spheres 140 approximately having the second screening size fall into the receiving space C1, and that excess refractive spheres that have not fallen into the receiving space C1 pass through the aperture H3 of the third screening unit 260 and are recovered by the recovery unit 270.

[0041] Please refer to again Figure 1 In this embodiment, after placing the refractive spheres 140 into the accommodating spaces C1, the manufacturing method of the display panel further includes providing a filling layer 150 to these accommodating spaces C1, such that the filling layer 150 is filled between the refractive spheres 140, the second screening unit 220 (i.e., the patterned structure layer 120), and the carrier plate 250 (such as the circuit board 110). Figure 4 In some embodiments, at least a portion of these accommodating spaces C1 are interconnected. Figure 4 (The example shown is three interconnected), and the filling layer 150 (i.e., the transparent material filled into the accommodating space C1) Figure 4 (Not shown in the diagram) These accommodating spaces C1 are also integrally connected. For example, the material of the filling layer 150 can be dripped in from the connection channel J1 between two adjacent accommodating spaces C1, filling the space and connection channel J1 between the refractive spheres 140, the patterned structure layer 120, and the circuit board 110, so that the cured filling layer 150 is integrally connected within these accommodating spaces C1. Furthermore, in Figure 4In the three interconnected accommodating spaces C1, the three micro-light-emitting chips 130 can be red, green, and blue micro-light-emitting chips, respectively, and their sizes can be the same or different. When the sizes of the three micro-light-emitting chips 130 are different, the size of the three accommodating spaces C1 (i.e., the exposure area determined by the patterned structure layer 120) can also vary with the size of the three micro-light-emitting chips 130 due to the light conditions, and thus the sizes of the refractive spheres 140 placed in the three accommodating spaces C1 of different sizes can also be different. For example, three refractive spheres 140 of different sizes can be selected and placed into the accommodating spaces C1 from largest to smallest. This ensures that each accommodating space C1 can accommodate a refractive sphere 140 of the corresponding size, preventing a small refractive sphere 140 from being placed in a large accommodating space C1.

[0042] Then, please refer to Figure 1 An optical adhesive layer 170 is used to cover the patterned structure layer 120, the filler layer 150, and the refractive sphere 140. In another embodiment, the filler layer 150 may be omitted, and the optical adhesive layer 170 may be directly used to fill the spaces between the refractive spheres 140, the patterned structure layer 120, and the circuit board 110, thereby covering the patterned structure layer 120, the filler layer 150, and the refractive sphere 140. In this case, in one embodiment, the refractive index of the optical adhesive layer 170 is, for example, 1.5, but the invention is not limited thereto. Compared to not using the filler layer 150 and instead allowing air to exist between the refractive spheres 140, the patterned structure layer 120, and the circuit board 110, the use of the filler layer 150 or the optical adhesive layer 170 to fill these spaces can further improve the light extraction efficiency.

[0043] After this, the light-transmitting substrate 160 is placed on the optical adhesive layer 170, thus completing the manufacturing of the display panel 100.

[0044] In the manufacturing method of the display panel in this embodiment, the lens is formed by placing a refractive sphere 140 instead of the photoresist reflow process of the prior art. Therefore, a pre-planarization layer process is not required, and the lens fabrication of the entire display panel 100 can be completed quickly. Furthermore, compared to the prior art, the refractive sphere 140 has two opposing refractive surfaces (i.e., Figure 1The upper and lower halves of the sphere 142 effectively enhance the brightness of the display panel 100. Because of the effectively improved light-gathering effect, the refractive sphere 140 does not need to significantly cover an area exceeding the micro-light-emitting chip 130. Therefore, the manufacturing method of the display panel in this embodiment can be applied to manufacturing display panels 100 with high pixel density. Furthermore, the size and position of the refractive sphere 140 can be quickly changed, thus the manufacturing method of the display panel in this embodiment has lower optimization design costs.

[0045] Figure 9 This is a cross-sectional schematic diagram illustrating one step of a method for manufacturing a display panel according to another embodiment of the present invention. Please refer to... Figure 9 and Figure 3 The manufacturing method of the display panel in this embodiment is the same as... Figures 8A to 8I The manufacturing methods for the display panels are similar, but the main differences are as follows. In the manufacturing method of the display panel in this embodiment, as... Figure 9 As shown, the carrier plate 250a is an intermediate carrier plate, such as a light-transmitting substrate 160, on which a second screening unit 220 (i.e., patterned structure layer 120) may be provided. After the refractive spheres 140 enter the receiving spaces C1, a filler layer 150 can be provided, filling the space between the refractive spheres 140, the second screening unit 220 (i.e., patterned structure layer 120), and the carrier plate 250 (i.e., light-transmitting substrate 160). After the filler layer 150 cures, the refractive spheres 140 are fixed to the light-transmitting substrate 160. In the following steps, it is applicable to perform actions such as... Figure 3 The step of combining the flip carrier 250a (transparent substrate 160) with the circuit board 110 as described in the embodiment.

[0046] Compared to not using a filling layer 150 and instead allowing air to exist between the refractive spheres 140, the patterned structure layer 120, and the carrier plate 250a, the aforementioned use of a filling layer 150 or an optical adhesive layer 170 to fill this space can avoid the unexpected impact of air on the light refraction path, further improving light extraction efficiency. Here, it is preferable to choose a filling layer 150 with higher fluidity (e.g., a refractive index of 1.3) to minimize the air remaining between the carrier plate 250a (i.e., the light-transmitting substrate 160) and the refractive spheres 140 due to the lower fluidity of the optical adhesive layer 170 (e.g., a refractive index of 1.5).

[0047] Figure 10A This is a perspective view illustrating the relative relationship between the refractive sphere, the patterned structural layer, and the accommodating space of a display panel according to another embodiment of the present invention. Figure 10B To show Figure 10A A top view schematic diagram showing the relative relationship between the micro-light-emitting chips in the display panel and the accommodating space. Please refer to... Figure 10Aand Figure 10B The display panel in this embodiment and Figure 4 The display panel of this embodiment is similar to that of the previous embodiment, but the main differences are as follows. In the display panel of this embodiment, the patterned structure layer 120d further includes an island structure 122d with an independent outer peripheral sidewall 123d. Each refractive sphere 140 is correspondingly disposed in the receiving space C1, and a connecting channel J1 is provided between any two adjacent receiving spaces C1. Part of the outer peripheral sidewall 123d can serve as a sidewall of the receiving space C1, which can contact the refractive sphere 140 and confine the refractive sphere 140 within the receiving space C1, while another part of the outer peripheral sidewall 123d can serve as a sidewall of the connecting channel J1.

[0048] The width of the connecting channel J1 can be smaller than the diameter of the refractive sphere 140 to prevent the refractive sphere 140 from falling in. There is no micro-light-emitting chip 130 below the connecting channel J1; it can be exposed by the refractive sphere 140 to serve as an inlet for the material of the filling layer 150. Because the material of the filling layer 150 is fluid, it flows through the connecting channel J1 into each accommodating space C1, thus ensuring that the filling layer 150 is integrally connected to each accommodating space C1 and each connecting channel J1.

[0049] Figure 11A This is a perspective view illustrating the relative relationship between the refractive sphere, the patterned structural layer, and the accommodating space of a display panel according to another embodiment of the present invention. Figure 11B To show Figure 11A A top view schematic diagram showing the relative relationship between the micro-light-emitting chips in the display panel and the accommodating space. Please refer to... Figure 11A and Figure 11B The display panel in this embodiment and Figure 10A The display panel of this embodiment is similar to that of the previous embodiment, but the main differences are as follows. In the display panel of this embodiment, the island structure 122e of the patterned structure layer 120e is columnar, for example cylindrical, and its volume ratio is... Figure 10A The island-shaped structure 122d is small, but the width of the connecting channel J1e is still smaller than the diameter of the refractive sphere 140. Furthermore, this embodiment does not limit the placement of a micro-light-emitting chip 130 in each accommodating space C1; for example… Figure 11B The rightmost accommodating space C1 does not contain a micro light-emitting chip 130.

[0050] Figures 12A to 12E It shows Figure 8F Various possible variations of the steps, and Figures 13A to 13C It shows Figure 8H Various possible variations of the steps are described below. Please refer to the following examples first. Figure 12AIn this embodiment, the refractive sphere 140 can be placed in the liquid 50, and the oscillation unit 240 drives the second screening unit 220 to oscillate via ultrasonic oscillation, achieving the effect of fluid ultrasonic vibration, so that the refractive sphere 140 of appropriate size falls into the receiving space C1 of the second screening unit 220. Please refer to... Figure 12B , and Figure 12A The embodiments are similar, but the main difference is that a shaker 240f replaces the oscillation unit 240. The shaking of the shaker 240f drives the second screening unit 220 to oscillate, achieving a fluid oscillation effect, allowing the appropriately sized refractive sphere 140 to fall into the receiving space C1 of the second screening unit 220. Please refer to... Figure 12C This embodiment is similar to Figure 12B In the embodiments described, a shaker 240f is used; however, the refractive sphere 140 exists in the air rather than in the liquid 50, thus achieving the effect of physical oscillation of the dry powder. Please refer to... Figure 12D This embodiment is similar to Figure 12A In the embodiments described, ultrasonic oscillation is used; however, the refractive sphere 140 exists in air rather than in liquid 50, thus achieving the effect of dry powder ultrasonic oscillation. Please refer to... Figure 12E In this embodiment, the refractive sphere 140 is attached to the temporary substrate 70 via the adhesive layer 60, and the laser beam 80 is focused on the adhesive layer 60 to achieve the effect of debonding, causing the refractive sphere 140 to fall into the receiving space C1. That is to say, in addition to utilizing... Figures 12A to 12D Physical vibration methods are used to position the refractive sphere 140 in each accommodating space C1. For a few missed accommodating spaces C1, laser mass repair technology can be used to transfer the refractive sphere 140 to a specific accommodating space C1.

[0051] Please refer to Figure 13A In this embodiment, a scraper 92 can be used to scrape away excess refractive spheres 140 that have not entered or cannot enter the accommodating space C1. Please refer to... Figure 13B In this embodiment, the thrust of fluid 94 (such as liquid) can be used to push away and remove excess refractive spheres 140 that have not entered or cannot enter the accommodating space C1. Please refer to... Figure 13C In this embodiment, the thrust of the airflow 96 can be used to blow away and remove excess refractive spheres 140 that have not entered or cannot enter the accommodating space C1.

[0052] In summary, in the display panel and manufacturing method of the embodiments of the present invention, the use of a refractive sphere as a lens facilitates the rapid completion of lens fabrication for the entire display panel, eliminating the need for photoresist reflow lenses and pre-planarization processes. Furthermore, the refractive sphere provides a secondary refraction converging effect for light from the micro-light-emitting chip, significantly reducing the area required by the refractive sphere while effectively improving the brightness of the display panel, thus balancing the brightness and size requirements of the micro-display. In addition, compared to the reflow process, which may be limited or complex due to differences in pixel area size, the embodiments of the present invention only require changing the size of the refractive sphere and the position of its accommodating space to quickly adjust the design, resulting in lower optimization design costs.

[0053] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A display panel, characterized in that, include: The circuit board is defined with multiple pixel regions; A patterned structure layer is disposed on the circuit board to separate the plurality of pixel regions and to form a plurality of accommodating spaces corresponding to the plurality of pixel regions respectively; Multiple micro-light-emitting chips are connected to the circuit substrate and are respectively disposed in the multiple accommodating spaces corresponding to the multiple pixel regions; Multiple refractive spheres are disposed on the side of the multiple micro-light-emitting chips away from the circuit board, and each of the refractive spheres is respectively housed in one of the multiple accommodating spaces, wherein each of the refractive spheres has a spherical surface, and the spherical surface is at a distance from the micro-light-emitting chip on the side facing the corresponding micro-light-emitting chip, and the distance increases from the center of the spherical surface to the edge of the spherical surface; as well as A filling layer, wherein the filling layer fills the space between the patterned structure layer and each of the refractive spheres in a direction parallel to the surface of the circuit substrate, and the materials of the filling layer, the patterned structure layer, and the plurality of refractive spheres are all different.

2. The display panel according to claim 1, characterized in that, Each of the aforementioned refractive spheres directly contacts the corresponding micro-light-emitting chip.

3. The display panel according to claim 1, characterized in that, In a direction perpendicular to the surface of the circuit substrate, the filling layer at least fills the space between each of the refractive spheres and the corresponding micro-light-emitting chip.

4. The display panel according to claim 1, characterized in that, It also includes a light-transmitting substrate disposed on the side of the plurality of micro light-emitting chips away from the circuit substrate, and the patterned structure layer is connected to the light-transmitting substrate.

5. The display panel according to claim 4, characterized in that, It also includes an optical adhesive layer disposed between the patterned structure layer and the plurality of micro-light-emitting chips.

6. The display panel according to claim 5, characterized in that, It also includes a planarization layer that covers the plurality of micro light-emitting chips, and the planarization layer is disposed between the optical adhesive layer and the circuit substrate.

7. The display panel according to claim 4, characterized in that, Each of the aforementioned refractive spheres is in direct contact with the light-transmitting substrate.

8. The display panel according to claim 4, characterized in that, In a direction perpendicular to the surface of the circuit substrate, the filling layer fills the space between each of the refractive spheres and the light-transmitting substrate.

9. The display panel according to claim 1, characterized in that, The filling layer is a light-transmitting material and is disposed at least on the side of each sphere away from the corresponding micro-light-emitting chip.

10. The display panel according to claim 9, characterized in that, The patterned structure layer is a light-transmitting material, and the refractive index of the filling layer is less than that of the patterned structure layer.

11. The display panel according to claim 1, characterized in that, The patterned structure layer is a light-reflecting layer, a light-absorbing layer, or a light-transmitting layer.

12. The display panel according to claim 1, characterized in that, From a viewing angle perpendicular to the surface of the circuit board, the patterned structure layer conformally surrounds the plurality of refractive spheres.

13. The display panel according to claim 1, characterized in that, Each of the plurality of micro-light-emitting chips has a light-emitting layer parallel to the circuit substrate. In a direction parallel to the surface of the circuit substrate, at least a portion of the geometric center of the light-emitting layer has a first offset relative to the geometric center of the micro-light-emitting chip and a second offset relative to the geometric center of the accommodating space, and the first offset is greater than the second offset.

14. A method for manufacturing a display panel, characterized in that, include: A plurality of refractive spheres are provided, the plurality of refractive spheres having different sizes; A first filtering unit and a second filtering unit are provided, wherein the first filtering unit has a first filtering size and the second filtering unit has a second filtering size that is greater than or equal to the first filtering size; The plurality of refractive spheres are placed into the first screening unit to obtain a portion of the plurality of refractive spheres having a size greater than or equal to the first screening size; A carrier plate is provided, and the second screening unit is combined with the carrier plate so that the second screening unit forms a plurality of receiving spaces on the carrier plate; as well as The plurality of refractive spheres having a first screening size or larger are placed into the second screening unit, so that the plurality of refractive spheres enter the plurality of receiving spaces via the second screening unit.

15. The method for manufacturing a display panel according to claim 14, characterized in that, The second filtering unit is a patterned structure layer.

16. The method for manufacturing a display panel according to claim 15, characterized in that, In the step of combining the second screening unit with the carrier plate, the second screening unit is coated and formed on the carrier plate, and the second screening size is formed by a patterning process.

17. The method for manufacturing a display panel according to claim 16, characterized in that, The carrier board is a circuit board, which has multiple pixel regions corresponding to the multiple accommodating spaces. Each pixel region is provided with at least one micro light-emitting chip, and the second screening unit exposes the multiple micro light-emitting chips through a patterning process.

18. The method for manufacturing a display panel according to claim 16, characterized in that, The carrier plate is a light-transmitting substrate, and the manufacturing method of the display panel further includes: Provide circuit boards; and After the plurality of refractive spheres enter the plurality of accommodating spaces, the plurality of refractive spheres are sealed between the light-transmitting substrate and the circuit substrate.

19. The method for manufacturing a display panel according to claim 14, characterized in that, Also includes: A filling layer is provided to the plurality of accommodating spaces such that the filling layer is filled between the plurality of refractive spheres, the second screening unit, and the carrier plate.

20. The method for manufacturing a display panel according to claim 19, characterized in that, At least a portion of the plurality of accommodating spaces are connected to each other, and the filling layer is also integrally connected within the connected plurality of accommodating spaces.

21. The method for manufacturing a display panel according to claim 19, characterized in that, Both the filling layer and the second screening unit are light-transmitting materials, and the refractive index of the filling layer is less than that of the second screening unit.

22. The method for manufacturing a display panel according to claim 14, characterized in that, Also includes: Provides an oscillation unit; as well as When the plurality of refractive spheres are placed into the first screening unit or the second screening unit, the oscillation unit is activated so that the oscillation unit acts on the first screening unit or the second screening unit.

23. The method for manufacturing a display panel according to claim 14, characterized in that, Also includes: A third filtering unit is provided, which has a third filtering size that is larger than the second filtering size; Place the second screening unit and the carrier plate into the third screening unit; as well as A recycling unit is provided and is positioned on one side of the third screening unit to recycle the plurality of refractive spheres that have not entered the plurality of pixel regions.

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