Display device and method of manufacturing display device

Patent metadata

Field	Value
Publication number	US-11410975-B2
Application number	US-202016796083-A
Country	US
Kind code	B2
Filing date	Feb 20, 2020
Priority date	Feb 20, 2019
Publication date	Aug 9, 2022
Grant date	Aug 9, 2022

Abstract

A method of manufacturing a display device 1 includes: providing a substrate including at least one sub-pixel defined therein and a first wiring disposed for the sub-pixel, and the light-emitting element that includes a first electrode disposed on a lower surface and a second electrode disposed on at least two lateral surfaces intersecting with each other; mounting the light-emitting element on the substrate and electrically connecting the first electrode to the first wiring; forming a resin member covering the at least one light-emitting element, on the substrate, exposing a portion of the second electrode from an upper surface of the resin member by removing an upper portion of the resin member; and forming a second wiring with a mesh shape on the resin member such that a portion of the second wiring is disposed on the light-emitting element to electrically connect the second wiring to the second electrode.

First claim

The invention claimed is:

1. A method of manufacturing a display device, the method comprising:
providing a substrate and at least one light-emitting element, wherein
the substrate comprises sub-pixels, a first wiring disposed for at least one of the sub-pixels and an electrode disposed between the sub-pixels, the first wiring being flat, and
the at least one light-emitting element comprises at least two lateral surfaces intersecting with each other and a lower surface, wherein
a first electrode disposed on the lower surface, and
a second electrode disposed on the at least two lateral surfaces;

mounting the at least one light-emitting element on the substrate and electrically connecting the first electrode to the first wiring;
forming a resin member on the substrate, the resin member covering the at least one light-emitting element and the electrode;
exposing a portion of the second electrode from an upper surface of the resin member by removing an upper portion of the resin member, and exposing at least a portion of the electrode from a lateral surface of the resin member by removing a portion of the resin member, the electrode being disposed under the lower surface of the at least one light-emitting element, and the electrode being disposed on a same plane as the first wiring; and
forming a second wiring with a mesh shape on the resin member such that a portion of the second wiring is disposed on the at least one light-emitting element to electrically connect the second wiring to the second electrode and the electrode, wherein the second wiring is disposed on the upper surface of the resin member and on the lateral surface of the resin member, and the second wiring is connected to the electrode disposed on both sides of the resin member.

2. The method of manufacturing a display device according to claim 1 ,
wherein the at least one light-emitting element includes a semiconductor member, and
wherein the second electrode is disposed around the semiconductor member in a top view.

3. The method of manufacturing a display device according to claim 1 ,
wherein the at least one light-emitting element includes a semiconductor member having an upper surface, and
wherein the second electrode is disposed also on a portion of the upper surface of the semiconductor member.

4. The method of manufacturing a display device according to claim 1 , wherein the at least one light-emitting element has a rectangular shape in a top view.

5. The method of manufacturing a display device according to claim 1 , wherein the second wiring comprises a first linear portion extending in a first direction and a second linear portion extending in a second direction that intersects the first direction and being connected to the first linear portion.

6. The method of manufacturing a display device according to claim 2 , wherein the second wiring comprises a first linear portion extending in a first direction and a second linear portion extending in a second direction that intersects the first direction and being connected to the first linear portion.

7. The method of manufacturing a display device according to claim 3 , wherein the second wiring comprises a first linear portion extending in a first direction and a second linear portion extending in a second direction that intersects the first direction and being connected to the first linear portion.

8. The method of manufacturing a display device according to claim 1 ,
wherein the at least one light-emitting element comprises a plurality of light-emitting elements, and
wherein plurality of the light-emitting elements are mounted on the at least one sub-pixel.

9. The method of manufacturing a display device according to claim 2 ,
wherein the at least one light-emitting element comprises a plurality of light-emitting elements, and
wherein the plurality of light-emitting elements are mounted on the at least one sub-pixel.

10. The method of manufacturing a display device according to claim 3 ,
wherein the at least one light-emitting element comprises a plurality of light-emitting elements, and
wherein the plurality of light-emitting elements are mounted on the at least one sub-pixel.

11. The method of manufacturing a display device according to claim 6 , wherein the at least one light-emitting element comprises a defective light-emitting element, and the method further comprising
disconnecting the defective light-emitting element from the second wiring.

12. The method of manufacturing a display device according claim 1 ,
wherein the at least one sub-pixel comprises a plurality of sub-pixels,
wherein the at least one light-emitting element comprises a plurality of light-emitting elements,
wherein in the step of forming the resin member, the resin member covers the plurality of light-emitting elements mounted on the plurality of sub-pixels, and
wherein in the exposing step, the resin member is divided into each of the sub-pixels.

13. A display device comprising:
a substrate comprising sub-pixels;
a first wiring disposed for each of the sub-pixels on the substrate, the first wiring being flat;
an electrode disposed between the sub-pixels on the substrate;
at least one light-emitting element mounted for each of the sub-pixels on the substrate;
a resin member covering a lower portion of the at least one light-emitting element and the first wiring the resin member having an upper surface and a lateral surface; and
a second wiring with a mesh shape disposed on the resin member such that a portion of the second wiring is disposed on the at least one light-emitting element, the second wiring being disposed on the upper surface of the resin member and on the lateral surface of the resin member,
wherein the at least one light-emitting element comprises
a semiconductor member having a lower surface and at least two lateral surfaces that intersect with each other,
a first electrode disposed on the lower surface and electrically connected to the first wiring, and
a second electrode disposed on the at least two lateral surfaces, a portion of the second electrode being exposed from an upper surface of the resin member,

wherein the second wiring is electrically connected to the portion of the second electrode that is exposed from the resin member and to the electrode disposed on both sides of the resin member,
wherein the electrode is disposed under the lower surface of the semiconductor member of the at least one light-emitting element, and
wherein the electrode being disposed on a same plane as the first wiring.

14. The display device according to claim 13 ,
wherein the at least one light-emitting element further includes an insulating light reflective layer disposed between the lateral surfaces of the semiconductor member and the second electrode,
wherein the second electrode is disposed at a periphery of the semiconductor member in a top view, and
wherein the second electrode is electrically connected to the lower surface of the semiconductor member.

15. The display device according to claim 13 ,
wherein the at least one light-emitting element comprises a plurality of light-emitting elements, and
wherein the plurality of light-emitting elements are mounted on the at least one sub-pixel.

16. The display device according to claim 14 ,
wherein the at least one light-emitting element comprises a plurality of light-emitting elements, and
wherein the plurality of light-emitting elements are mounted on the at least one sub-pixel.

17. The display device according to claim 15 ,
wherein the plurality of light-emit

Assignees

• Nichia Corp

Inventors

• Ichikawa Kinya
• Kadan Katsuyoshi
• Sano Masahiko
• Hirose Ryohei
• Yoneda Hiroshi

Classifications

• H10W90/00 Primary

  Package configurations · CPC title

• H10P74/232

  comprising connection or disconnection of parts of a device in response to a measurement · CPC title

• H10H20/0364

  of interconnections · CPC title

• H10H20/857

  Interconnections, e.g. lead-frames, bond wires or solder balls · CPC title

• H10H20/841

  Reflective coatings, e.g. dielectric Bragg reflectors · CPC title