Substrate with topological features for steering fluidic assembly LED disks

• US 10,431,718 B2
• Filed: 07/02/2018
• Issued: 10/01/2019
• Est. Priority Date: 07/27/2016
• Status: Active Grant

• Current Assignee: Elux Inc.
• Original Assignee: Elux Inc.
• Inventors: Crowder, Mark Albert, Schuele, Paul J., Zhan, Changqing, Sasaki, Kenji Alexander, Ulmer, Kurt Michael
• Primary Examiner(s): Jahan, Bilkis
• Application Number:
  US16/025,167
• Publication Number:
  US 20180309023A1
• Time in Patent Office: 456 Days
• Field of Search: None
• CPC Class Codes: H01L 2224/95 at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips
• CPC Class Codes: H01L 2224/95101 in a liquid medium
• CPC Class Codes: H01L 27/156 two-dimensional arrays
• CPC Class Codes: H01L 2933/0066 relating to arrangements for conducting electric current to or from the semiconductor body
• CPC Class Codes: H01L 33/24 of the light emitting region, e.g. non-planar junction
• 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

Abstract

Embodiments are related to integrated circuit (IC) fabrication and, more particularly, to a fluidic assembly process for the placement of light emitting diodes on a direct-emission display substrate.

Claims

1. A display panel, the display panel comprising:

a substrate with a top surface;

a material layer disposed over the top surface of the substrate, wherein the material layer includes;

a plurality of wells, and wherein each of the plurality of wells extends to a first depth into the material layer;

at least one object steering feature surrounding two or more of the plurality of wells, wherein the object steering feature extends a second depth into the material layer, and wherein the second depth is less than the first depth; and

wherein the material layer includes a first sub-layer disposed over the top surface of the substrate and a second sub-layer disposed over the first sub-layer.

2. The panel of claim 1, wherein a thickness of the first sub-layer is greater than a thickness of the second sub-layer layer.

3. The panel of claim 1, wherein the first depth is a thickness of the first sub-layer, and wherein the second depth is a thickness of the second sub-layer layer.

4. The panel of claim 1, wherein the first sub-layer comprises a first material and the second sub-layer comprises a second material.

5. The panel of claim 4, wherein the first material is the same as the second material.

6. The panel of claim 4, wherein the second material is removable.

7. The panel of claim 1, wherein the at least one object steering feature is a slot with a cross-section greater than an opening of each of the two or more of the plurality of wells.

8. The panel of claim 7, wherein the two or more of the plurality of wells is part of a column of wells.

9. The panel of claim 7, wherein the two or more of the plurality of wells each has a perimeter;

and wherein the at least one object steering feature has a sidewall having through-indentations coextensive with at least a portion of the perimeter of each of the two or more of the plurality of wells.

10. The panel of claim 7, wherein the substrate includes interconnect pads aligned in a plurality of rows.

11. The panel of claim 10, the panel further comprising:

a light emitting diode (LED) disk situated in each of the two or more of the plurality of wells, wherein each LED disk has a cross-sectional width less than a cross-sectional opening of each of the two or more of the plurality of wells, and a surface with a first contact to make an electrical connection with one of the interconnect pads.

12. The panel of claim 11, wherein the material layer includes a first sub-layer disposed over the top surface of the substrate and having a first thickness, and a second sub-layer disposed over the first sub-layer and having a first thickness, and wherein the LED disks have about the same thickness as the first thickness.

13. The panel of claim 12, wherein the panel further comprises:

an insulator material filling the at least one object steering feature, with vias exposing a second contact of each of the LED disks; and

a plurality of top electrically conductive traces, with each top conductive trace connected to the second contact of each of the LED disks in a corresponding column of wells.

14. The panel of claim 1, wherein the substrate includes a through-hole via (THV) co-located with each of the plurality of wells.

15. A display panel, the panel comprising:

a substrate with a top surface;

a material layer disposed over the top surface of the substrate, wherein the material layer includes a plurality of wells extending into the material layer and exposing the top surface of the substrate; and

a material steering structure disposed over the material layer, wherein the material steering structure surrounds two or more of the plurality of wells, and wherein the two or more of the plurality of wells is part of a column of wells.

16. The panel of claim 15, wherein the material steering structure is a slot with a cross-section greater than an opening of each of the two or more of the plurality of wells.

17. The panel of claim 15, wherein the two or more of the plurality of wells each have a perimeter;

and wherein the material steering structure has a sidewall having through-indentations coextensive with at least a portion of the perimeter of each of the two or more of the plurality of wells.

18. The panel of claim 15, wherein the substrate includes interconnect pads aligned in a plurality of rows.

19. The panel of claim 18, the panel further comprising:

a light emitting diode (LED) disk situated in each of the two or more of the plurality of wells, wherein each LED disk has a cross-sectional width less than a cross-sectional opening of each of the two or more of the plurality of wells, and a bottom surface with a lower contact to make an electrical connection with one of the interconnect pads.

20. The panel of claim 15, wherein the substrate includes a through-hole via (THV) co-located with each of the plurality of wells.

21. A display panel, the display panel comprising:

a substrate with a planar surface;

a layer disposed over the planar surface of the substrate, wherein the layer includes a plurality of wells extending a first depth into the layer; and

a material steering structure disposed over the layer and extending a second depth from the layer, wherein the material steering structure surrounds two or more of the plurality of wells, and wherein the material steering structure is a slot with a cross-section greater than an opening of either of the two or more of the plurality of wells.

22. The display panel of claim 21, wherein the two or more of the plurality of wells is part of a column of wells.

23. The display panel of claim 22, wherein the two or more of the plurality of wells each has a perimeter;

and wherein the at least one object steering feature has a sidewall having through-indentations coextensive with at least a portion of the perimeter of each of the two or more of the plurality of wells.

24. The display panel of claim 22, wherein the substrate includes interconnect pads aligned in a plurality of rows.