Micro-printed display

• US 10,153,257 B2
• Filed: 03/10/2017
• Issued: 12/11/2018
• Est. Priority Date: 03/03/2016
• Status: Active Grant

• Current Assignee: X Display Company Technology Limited (Sensinnovat BVBA)
• Original Assignee: X-Celeprint Limited
• Inventors: Cok, Ronald S., Bower, Christopher Andrew, Meitl, Matthew, Prevatte, Jr., Carl Ray, Bonafede, Salvatore, Rotzoll, Robert R.
• Primary Examiner(s): Cao, Phat X
• Assistant Examiner(s): Vieira, Diana C
• Application Number:
  US15/456,273
• Publication Number:
  US 20170256522A1
• Time in Patent Office: 641 Days
• Field of Search: None
• CPC Class Codes: H01L 2224/18 High density interconnect [HDI] connectors; Manufacturing methods related thereto
• CPC Class Codes: H01L 2224/82001 involving a temporary auxiliary member not forming part of the bonding apparatus
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 25/50 Multistep manufacturing processes of assemblies consisting of devices, each device being of a type provided for in group H01L27/00 or H01L29/00 H01L21/50 takes precedence
• CPC Class Codes: H01L 33/62 Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls
• CPC Class Codes: H10K 59/129 Chiplets

Abstract

A micro-printed display includes a display substrate. An array of row conductors, an array of column conductors, and a plurality of micro-pixels are disposed on the display substrate. Each micro-pixel is uniquely connected to a row and a column conductor and comprises a pixel substrate separate from the display substrate and the pixel substrate of any other micro-pixel. Pixel conductors are patterned on each pixel substrate and one or more LEDs are disposed on or over the pixel substrate. Each LED is electrically connected to one or more of the pixel conductors and has an LED substrate separate from any other LED substrate, the display substrate, and any pixel substrate. A pixel controller disposed on the pixel substrate can control the LEDs. The micro-pixel can be electrically connected to the display substrate with connection posts. Redundant or replacement LEDs or micro-pixels can be provided on the pixel or display substrate.

Claims

1. A micro-printed display, comprising:

a display substrate;

an array of electrically conductive patterned row conductors formed on or over the display substrate, the row conductors extending in a row direction;

an array of electrically conductive patterned column conductors formed on or over the display substrate, the column conductors electrically isolated from the row conductors and extending in a column direction different from the row direction; and

a plurality of micro-pixels disposed over or on the display substrate, each micro-pixel uniquely electrically connected to a row conductor and a column conductor and wherein each micro-pixel comprises;

a pixel substrate separate, independent and distinct from the display substrate and the pixel substrate of any other micro-pixel, the pixel substrate having electrically conductive patterned pixel conductors provided thereon; and

(ii) one or more micro-light-emitting diodes (micro-LEDs) disposed on or over the pixel substrate, each micro-LED having an LED substrate separate, independent and distinct from any other LED substrate, the display substrate, and any pixel substrate, and each of the one or more micro-LEDs electrically connected to one or more of the pixel conductors,

wherein the micro-LEDs or the micro-pixels comprise a broken, fractured, or separated tether or both the micro-LEDs and the micro-pixels comprise a broken, fractured, or separated tether.

2. The micro-printed display of claim 1, wherein the one or more micro-LEDs each have connection posts that are electrically connected to the pixel conductors on the pixel substrate.

3. The micro-printed display of claim 1, wherein the micro-pixels each comprise a pixel controller disposed on or over the pixel substrate and having a controller substrate separate, independent and distinct from the display substrate, any pixel substrate, any micro-LED substrate, and any other controller substrate and wherein the pixel controller includes a control circuit that is electrically connected to and controls the one or more micro-LEDs of the micro-pixel.

4. The micro-printed display of claim 3, wherein the pixel controller has connection posts that are electrically connected to the pixel conductors on the pixel substrate.

5. The micro-printed display of claim 1, wherein each pixel substrate has a connection post that forms at least a part of the electrical connection to the row conductor and a connection post that forms at least a part of the electrical connection to the column conductor.

6. The micro-printed display of claim 1, wherein each pixel substrate comprises a redundant micro-LED corresponding to each micro-LED electrically connected in parallel or serial with the corresponding micro-LED.

7. The micro-printed display of claim 1, wherein each pixel substrate comprises a replacement LED location for each of the one or more micro-LEDs, the replacement micro-LED location electrically connected to one or more of the pixel conductors in parallel with the corresponding micro-LED.

8. The micro-printed display of claim 1, comprising a redundant micro-pixel corresponding to each micro-pixel disposed over or on the display substrate and electrically connected in parallel with the corresponding micro-pixel.

9. The micro-printed display of claim 1, comprising a replacement micro-pixel location for each of the micro-pixels, the replacement micro-pixel location electrically connected to a row conductor and a column conductor in parallel with the corresponding micro-pixel.

10. The micro-printed display of claim 1, wherein the row and column conductors have a width that is greater than the width of the pixel conductor and the row and column conductors have a lower resolution than the pixel conductors.

11. The micro-printed display of claim 1, comprising a plurality of row controllers disposed over or on the display substrate and electrically connected to the row conductors.

12. The micro-printed display of claim 11, wherein the row controllers are serially connected in a daisy chain.

13. The micro-printed display of claim 11, comprising a redundant row controller corresponding to each row controller disposed over or on the display substrate and electrically connected in parallel with the corresponding row controller.

14. The micro-printed display of claim 11, comprising a replacement row-controller location for each of the row controllers, the replacement row-controller location electrically connected in parallel with the corresponding row controller.

15. The micro-printed display of claim 1, comprising a plurality of column controllers disposed over or on the display substrate and electrically connected to the column conductors.

16. The micro-printed display of claim 15, wherein the column controllers are serially connected in a daisy chain.

17. The micro-printed display of claim 15, comprising a redundant column controller corresponding to each column controller disposed over or on the display substrate and electrically connected in parallel with the corresponding column controller.

18. The micro-printed display of claim 15, comprising a replacement column-controller location for each of the column controllers, the replacement column-controller location electrically connected in parallel with the corresponding column controller.

19. The micro-printed display of claim 1, wherein row conductors have row segments disposed between the column conductors and the micro-pixels comprise an electrical connection between adjacent row segments on opposite sides of the column conductors or wherein column conductors have column segments disposed between the row conductors and the micro-pixels comprise an electrical connection between adjacent column segments on opposite sides of the row conductors.

20. The micro-printed display of claim 1, wherein row conductors have row segments disposed between the column conductors and comprising jumpers that form an electrical connection between adjacent row segments on opposite sides of the column conductors or wherein column conductors have column segments disposed between the row conductors and comprising jumpers that form an electrical connection between adjacent column segments on opposite sides of the row conductors.

21. The micro-printed display of claim 20, wherein the jumper is a portion of the micro-pixel.

22. The micro-printed display of claim 20, wherein the jumper has a substrate separate, independent, and distinct from the micro-pixel.

23. A micro-printed display, comprising:

a display substrate;

an array of electrically conductive patterned row conductors formed on or over the display substrate, the row conductors extending in a row direction;

an array of electrically conductive patterned column conductors formed on or over the display substrate, the column conductors electrically isolated from the row conductors and extending in a column direction different from the row direction; and

a plurality of micro-pixels disposed over or on the display substrate, each micro-pixel uniquely electrically connected to a row conductor and a column conductor and wherein each micro-pixel comprises;

(iii) a pixel substrate separate, independent and distinct from the display substrate and the pixel substrate of any other micro-pixel, the pixel substrate having electrically conductive patterned pixel conductors provided thereon; and

(iv) one or more micro-light-emitting diodes (micro-LEDs) disposed on or over the pixel substrate, each micro-LED having an LED substrate separate, independent and distinct from any other LED substrate, the display substrate, and any pixel substrate, and each of the one or more micro-LEDs electrically connected to one or more of the pixel conductors,

wherein the row and column conductors have a width that is greater than the width of the pixel conductor and the row and column conductors have a lower resolution than the pixel conductors.

24. A micro-printed display, comprising:

a display substrate;

an array of electrically conductive patterned row conductors formed on or over the display substrate, the row conductors extending in a row direction;

an array of electrically conductive patterned column conductors formed on or over the display substrate, the column conductors electrically isolated from the row conductors and extending in a column direction different from the row direction; and

a plurality of micro-pixels disposed over or on the display substrate, each micro-pixel uniquely electrically connected to a row conductor and a column conductor and wherein each micro-pixel comprises;

a pixel substrate separate, independent and distinct from the display substrate and the pixel substrate of any other micro-pixel, the pixel substrate having electrically conductive patterned pixel conductors provided thereon; and

(ii) one or more micro-light-emitting diodes (micro-LEDs) disposed on or over the pixel substrate, each micro-LED having an LED substrate separate, independent and distinct from any other LED substrate, the display substrate, and any pixel substrate, and each of the one or more micro-LEDs electrically connected to one or more of the pixel conductors; and

either (a) a plurality of row controllers disposed over or on the display substrate and electrically connected to the row conductors, wherein the row controllers are serially connected in a daisy chain, or (b) a plurality of column controllers disposed over or on the display substrate and electrically connected to the column conductors, wherein the column controllers are serially connected in a daisy chain, or both (a) and (b).