Method for the fluidic assembly of emissive displays
First Claim
1. A fluidic assembly method for the fabrication of emissive displays, the method comprising:
- providing an emissive substrate with a top surface, a plurality of wells formed in the top surface, each well comprising a bottom surface with a first electrical interface, and a matrix of column and row traces forming a first plurality of column/row intersections, where each column/row intersection is associated with a corresponding well;
providing a first liquid suspension with a plurality of first type light emitting diodes (LEDs), each first type LED comprising a post, made from an insulator, extending from a surface;
flowing the first liquid suspension across the emissive substrate top surface;
capturing the first type of LEDs in the wells, oriented so that the posts are exposed and extending out of well openings in the emissive substrate top surface;
providing a second liquid suspension with a plurality of second type LEDs, each second type of LED comprising a post, made from an insulator, extending from a surface;
flowing the second liquid suspension across the emissive substrate top surface;
capturing the second type of LEDs in the wells, oriented so that the posts are exposed and extending out of well openings in the emissive substrate top surface;
performing a final annealing of the emissive substrate; and
,in response to the final annealing, electrically connecting LEDs to the first electrical interface of corresponding wells.
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Abstract
Fluidic assembly methods are presented for the fabrication of emissive displays. An emissive substrate is provided with a top surface, and a first plurality of wells formed in the top surface. Each well has a bottom surface with a first electrical interface. Also provided is a liquid suspension of emissive elements. The suspension is flowed across the emissive substrate and the emissive elements are captured in the wells. As a result of annealing the emissive substrate, electrical connections are made between each emissive element to the first electrical interface of a corresponding well. A eutectic solder interface metal on either the substrate or the emissive element is desirable as well as the use of a fluxing agent prior to thermal anneal. The emissive element may be a surface mount light emitting diode (SMLED) with two electrical contacts on its top surface (adjacent to the bottom surfaces of the wells).
153 Citations
28 Claims
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1. A fluidic assembly method for the fabrication of emissive displays, the method comprising:
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providing an emissive substrate with a top surface, a plurality of wells formed in the top surface, each well comprising a bottom surface with a first electrical interface, and a matrix of column and row traces forming a first plurality of column/row intersections, where each column/row intersection is associated with a corresponding well; providing a first liquid suspension with a plurality of first type light emitting diodes (LEDs), each first type LED comprising a post, made from an insulator, extending from a surface; flowing the first liquid suspension across the emissive substrate top surface; capturing the first type of LEDs in the wells, oriented so that the posts are exposed and extending out of well openings in the emissive substrate top surface; providing a second liquid suspension with a plurality of second type LEDs, each second type of LED comprising a post, made from an insulator, extending from a surface; flowing the second liquid suspension across the emissive substrate top surface; capturing the second type of LEDs in the wells, oriented so that the posts are exposed and extending out of well openings in the emissive substrate top surface; performing a final annealing of the emissive substrate; and
,in response to the final annealing, electrically connecting LEDs to the first electrical interface of corresponding wells. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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26. A fluidic assembly method for the fabrication of emissive displays, the method comprising:
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providing an emissive substrate with a top surface, a plurality of wells formed in the top surface, each well comprising a bottom surface with a first electrical interface, and a matrix of column and row traces forming a first plurality of column/row intersections, where each column/row intersection is associated with a corresponding well; providing a first liquid suspension with a first type of emissive elements, each first type of emissive element having a single post centered on the bottom surface; flowing the first liquid suspension across the emissive substrate top surface; capturing the first type of emissive elements in the wells, surface orienting the first type of emissive element top surfaces directly overlying the well bottom surfaces, oriented so that the posts are exposed and extending out of well openings in the emissive substrate top surface, in response to the emissive element posts; providing a second liquid suspension with a second type of emissive elements, each second type of emissive element having a single post centered on the bottom surface; flowing the second liquid suspension across the emissive substrate top surface; capturing the second type of emissive elements in the wells, surface orienting the second type of emissive element top surfaces directly overlying the well bottom surfaces, oriented so that the posts are exposed and extending out of well openings in the emissive substrate top surface, in response to the emissive element posts; performing a final annealing of the emissive substrate; and
,in response to the final annealing, electrically connecting the emissive elements to the first electrical interface of corresponding wells.
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27. A fluidic assembly method for the fabrication of emissive displays, the method comprising:
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providing an emissive substrate with a top surface, a plurality of wells formed in the top surface, each well comprising a bottom surface with a first electrical interface, and a matrix of column and row traces forming a first plurality of column/row intersections, where each column/row intersection is associated with a corresponding well; providing a first liquid suspension with a first type of vertical emissive elements having a top surface with a first electrical contact a bottom surface with a second electrical contact, and a post extending from the top surface; flowing the first liquid suspension across the emissive substrate top surface; capturing the first type of emissive elements in the wells, oriented so that the posts are exposed and extending out of well openings in the emissive substrate top surface; providing a second liquid suspension with a second type of vertical emissive elements having a top surface with a first electrical contact, a bottom surface with a second electrical contact, and a post extending from the top surface; flowing the second liquid suspension across the emissive substrate top surface; capturing the second type of emissive elements in the wells, oriented so that the posts are exposed and extending out of well openings in the emissive substrate top surface; performing a final annealing of the emissive substrate; and
,in response to the final annealing, electrically connecting the emissive elements to the first electrical interface of corresponding wells.
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28. A fluidic assembly method for the fabrication of emissive displays, the method comprising:
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providing an emissive substrate with a top surface, a plurality of wells formed in the top surface, each well comprising a bottom surface with a first electrical interface and a second electrical interface, and a matrix of column and row traces forming a first plurality of column/row intersections, where each column/row intersection is associated with a corresponding well; providing a first liquid suspension with a plurality of first type light surface mount light emitting diodes (LEDs), each first type surface mount LED comprising a bottom surface and a top surface, with a first electrical contact and a second electrical contact formed on the top surface, and with an insulator material post extending from the bottom surface; flowing the first liquid suspension across the emissive substrate top surface; capturing the first type of surface mount LEDs with the top surface directly overlying a corresponding well bottom surface; providing a second liquid suspension with a plurality of second type surface mount LEDs, each second type surface mount LED comprising a bottom surface and a top surface, with a first electrical contact and a second electrical contact formed on the top surface, and with an insulator material post extending from the bottom surface; flowing the second liquid suspension across the emissive substrate top surface; capturing the second type of surface mount LEDs with the top surface directly overlying a corresponding well bottom surface; performing a final annealing of the emissive substrate; and
,electrically connecting each first and second type surface mount LED first electrical contact to a corresponding well first electrical interface and each first and second type LED second electrical contact to a corresponding well second electrical interface.
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Specification