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 having a first shape and a plurality of wells having a second shape, different than the first shape, each well comprising a bottom surface with a first electrical interface, and providing 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 liquid suspension with a first type of emissive element having a third shape capable of filling the first shape wells, but incapable of filling the second shape wells, and a second type of emissive element having a fourth shape capable of filling the second shape wells, but incapable of filling the first shape wells, with each first and second type of emissive element having a single post centered on a surface;
flowing the liquid suspension across the emissive substrate top surface;
capturing the first type of emissive elements in the first shape wells and the second type of emissive elements in the second shape wells, oriented so that the posts of the first and second type of emissive elements are exposed and extending out of respective well openings in the emissive substrate top surface;
annealing the emissive substrate; and
,in response to the annealing, electrically connecting the first and second type emissive elements to the first electrical interface of corresponding wells.
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Accused Products
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
24 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 having a first shape and a plurality of wells having a second shape, different than the first shape, each well comprising a bottom surface with a first electrical interface, and providing 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 liquid suspension with a first type of emissive element having a third shape capable of filling the first shape wells, but incapable of filling the second shape wells, and a second type of emissive element having a fourth shape capable of filling the second shape wells, but incapable of filling the first shape wells, with each first and second type of emissive element having a single post centered on a surface; flowing the liquid suspension across the emissive substrate top surface; capturing the first type of emissive elements in the first shape wells and the second type of emissive elements in the second shape wells, oriented so that the posts of the first and second type of emissive elements are exposed and extending out of respective well openings in the emissive substrate top surface; annealing the emissive substrate; and
,in response to the annealing, electrically connecting the first and second type emissive elements 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)
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21. 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 having a first shape and a plurality of wells having a second shape, different than the first shape, each well comprising a bottom surface with a first electrical interface, and providing 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 liquid suspension with a first type of light emitting diode (LED) having a third shape capable of filling the first shape wells, but incapable of filling the second shape wells, and a second type of LED having a fourth shape capable of filling the second shape wells, but incapable of filling the first shape wells, wherein the first and second type of LEDs each have a post extending from a bottom surface; flowing the liquid suspension across the emissive substrate top surface; capturing the first type of LEDs in the first shape wells, surface orienting the first type of LED top surfaces directly overlying the first shape well bottom surfaces with the posts exposed and extending out of first shape well openings in the emissive substrate top surface in response to the first type of LED posts, and capturing the second type of LED in the second shape wells, surface orienting the second type of LED top surfaces directly overlying the second shape well bottom surfaces with the posts exposed and extending out of second shape well openings in the emissive substrate top surface in response to the second type of LED posts; annealing the emissive substrate; and
,in response to the annealing, electrically connecting the first and second type LEDs to the first electrical interface of corresponding wells.
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22. 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 having a first shape and a plurality of wells having a second shape, different than the first shape, each well comprising a bottom surface with a first electrical interface, and providing 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 liquid suspension comprising a first type of vertical emissive element having a third shape capable of filling the first shape wells, a top surface with a first electrical contact, a post extending from the top surface, and a bottom surface with a second electrical contact, wherein the first type of vertical emissive element is incapable of filling the second shape wells, and the liquid suspension also comprising a second type of emissive element having a fourth shape capable of filling the second shape wells, a top surface with a first electrical contact, a post extending from the top surface, and a bottom surface with a second electrical contact, wherein the second type of vertical emissive element is incapable of filling the first shape wells; flowing the liquid suspension across the emissive substrate top surface; capturing the first type of emissive elements in the first shape wells and the second type of emissive elements in the second shape wells with the posts exposed and extending out of respective well openings in the emissive substrate top surface; annealing the emissive substrate; and
,in response to the annealing, electrically connecting the first and second type emissive elements to the first electrical interface of corresponding wells.
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23. 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 having a first shape and a plurality of wells having a second shape, different than the first shape, each well comprising a bottom surface with a first electrical interface, and providing 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 liquid suspension with a first type of vertical emissive element having a third shape capable of filling the first shape wells, but incapable of filling the second shape wells, and a second type of vertical emissive element having a fourth shape capable of filling the second shape wells, but incapable of filling the first shape wells; wherein the first and second type vertical emissive elements each have a bottom surface with a first electrical contact and a top surface with a second electrical contact, with a post centered on the top surface; flowing the liquid suspension across the emissive substrate top surface; capturing the top surface of first type of vertical emissive elements in the first shape wells and the top surface of the second type of vertical emissive elements in the second shape wells, directly overlying corresponding well bottom surfaces; annealing the emissive substrate; and
,in response to the annealing, electrically connecting the first electrical contact of the first and second type vertical emissive elements to the first electrical interface of corresponding wells.
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24. 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 having a first shape and a plurality of wells having a second shape, different than the first shape, each well comprising a bottom surface with a first electrical interface and a second electrical interface, and providing 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 liquid suspension with a first type of surface mount emissive element having a third shape capable of filling the first shape wells, but incapable of filling the second shape wells, and a second type of surface mount emissive element having a fourth shape capable of filling the second shape wells, but incapable of filling the first shape wells; wherein the first and second type surface mount emissive elements each have a bottom surface and a top surface, with a first electrical contact and a second electrical contact formed on the top surface, and a post centered on the bottom surface; flowing the liquid suspension across the emissive substrate top surface; capturing the top surface of the first type of surface mount emissive elements directly overlying the bottom surface of the first shape wells and capturing the top surface of the second type of surface mount emissive elements directly overlying the bottom surface of the second shape wells; annealing the emissive substrate; and
,in response to the annealing, electrically connecting the first and second electrical contacts of the first and second type of surface mount emissive elements, respectively, to the first and second electrical interfaces of corresponding wells.
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Specification