System and 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 first 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 liquid suspension of light emitting diodes (LEDs), with each LED having a post, made from an insulator material, extending from a surface;
flowing the liquid suspension across the emissive substrate top surface;
capturing the LEDs in the wells, oriented so that the posts are exposed and extending out of well openings in the emissive substrate top surface;
annealing the emissive substrate; and
, in response to the annealing, electrically connecting each LED to the first electrical interface of a corresponding well, wherein flowing the liquid suspension across the substrate top surface includes flipping the orientation of inverted LEDs, from a post-down to a post-up orientation, in response to drag forces resulting from a moment of force about an LED surface edge creating a fixed point of rotation with respect to a substrate surface.
1 Assignment
0 Petitions
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).
-
Citations
28 Claims
-
1. A fluidic assembly method for the fabrication of emissive displays, the method comprising:
- providing an emissive substrate with a top surface, a first 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 liquid suspension of light emitting diodes (LEDs), with each LED having a post, made from an insulator material, extending from a surface;
flowing the liquid suspension across the emissive substrate top surface;
capturing the LEDs in the wells, oriented so that the posts are exposed and extending out of well openings in the emissive substrate top surface;
annealing the emissive substrate; and
, in response to the annealing, electrically connecting each LED to the first electrical interface of a corresponding well, wherein flowing the liquid suspension across the substrate top surface includes flipping the orientation of inverted LEDs, from a post-down to a post-up orientation, in response to drag forces resulting from a moment of force about an LED surface edge creating a fixed point of rotation with respect to a substrate surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 28)
- providing an emissive substrate with a top surface, a first 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;
-
19. A fluidic assembly method for the fabrication of emissive displays, the method comprising:
-
providing an emissive substrate with a top surface, a first plurality of wells formed in the top surface, each well comprising a bottom surface with a first electrical interface and sidewalls formed about orthogonal to the bottom surface, 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 liquid suspension of vertical light emitting diodes (LEDs) having a bottom surface with a first electrical contact, a top surface with a second electrical contact, and a post made from an insulator material extending from the vertical LED top surface; flowing the liquid suspension across the emissive substrate top surface; capturing the vertical LEDs bottom surfaces directly overlying corresponding well bottom surfaces; annealing the emissive substrate; in response to the annealing, electrically connecting each vertical LED first electrical contact to the first electrical interface of a corresponding well; and
,wherein flowing the liquid suspension across the substrate top surface includes flipping the orientation of inverted vertical LEDs, from a post-down to a post-up orientation, in response to drag forces resulting from a moment of force about a vertical LED top surface edge creating a fixed point of rotation with respect to a substrate surface. - View Dependent Claims (20)
-
-
21. A fluidic assembly method for the fabrication of emissive displays, the method comprising:
- providing an emissive substrate with a top surface, a first plurality of wells formed in the top surface, each well comprising a bottom eLux_00101_response48surface 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 liquid suspension of surface mount emissive elements having a bottom surface and a top surface, with a first electrical contact and a second electrical contact formed on the top surface, and with a single post centered on the surface mount emissive element bottom surface;
flowing the liquid suspension across the emissive substrate top surface;
capturing surface mount emissive element top bottom surfaces directly overlying corresponding well bottom surfaces;
annealing the emissive substrate; and
, in response to the annealing, electrically connecting each surface mount emissive element first electrical contact to a corresponding well first electrical interface and each surface mount emissive element second electrical contact to a corresponding well second electrical interface, wherein flowing the liquid suspension across the substrate top surface includes flipping the orientation of inverted surface mount emissive elements, from a post-down to a post-up orientation, in response to drag forces resulting from a moment of force about a surface mount emissive element bottom surface edge creating a fixed point of rotation with respect to a substrate surface. - View Dependent Claims (22)
- providing an emissive substrate with a top surface, a first plurality of wells formed in the top surface, each well comprising a bottom eLux_00101_response48surface 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;
-
23. A fluidic assembly method for the fabrication of emissive displays, the method comprising:
-
providing an emissive substrate with a top surface, a first 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 liquid suspension of emissive elements, with each emissive element having a single post centered on a surface; flowing the liquid suspension across the emissive substrate top surface and flipping the orientation of inverted emissive elements, from a post-down to a post-up orientation, in response to drag forces resulting from a moment of force about an emissive element surface edge creating a fixed point of rotation with respect to a substrate surface; capturing the emissive elements in the wells oriented so that the posts are exposed and extending out of well openings in the emissive substrate top surface; annealing the emissive substrate; and
,in response to the annealing, electrically connecting each emissive element to the first electrical interface of a corresponding well. - View Dependent Claims (24, 25, 26, 27)
-
Specification