LIQUID MANUFACTURING PROCESSES FOR PANEL LAYER FABRICATION
First Claim
1. A method for manufacturing a light-emitting panel comprising:
- providing a first substrate, the first substrate having a plurality of first conductors formed thereon;
disposing at least one micro-component of a plurality of micro-components at each of a plurality of first locations on the first substrate corresponding to the plurality of conductors, each micro-component adapted to emit radiation in response to electrical excitation;
electrically isolating the plurality of micro-components from each other; and
depositing a conductive film at a plurality of second locations adapted to interact with the first conductors to excite one or more selected micro-components.
6 Assignments
0 Petitions
Accused Products
Abstract
A method for manufacturing a light-emitting panel sandwiches a plurality of micro-components between two flexible substrates in a web configuration. Each micro-component contains a gas or gas-mixture capable of ionization when a sufficiently large voltage is supplied across the micro-component via at least two electrodes. The micro-components are disposed in sockets formed at pre-determined locations in a first dielectric substrate so that they are adjacent to electrodes imprinted in the first substrate. Dielectric layers and the conductors for acting as electrodes are formed using liquid processes or combined liquid and sheet processes, where liquid materials are applied to the surface of the underlying layer, then cured to complete the formation of layers. The assembled layers are coated with a protective coating and may include an RF shield. In one embodiment, patterning of the conductors is achieved by applying conductive ink using an ink jet process. In another embodiment, the conductors may be patterned photolithographically using a leaky optical waveguide as a contact mask.
-
Citations
26 Claims
-
1. A method for manufacturing a light-emitting panel comprising:
-
providing a first substrate, the first substrate having a plurality of first conductors formed thereon;
disposing at least one micro-component of a plurality of micro-components at each of a plurality of first locations on the first substrate corresponding to the plurality of conductors, each micro-component adapted to emit radiation in response to electrical excitation;
electrically isolating the plurality of micro-components from each other; and
depositing a conductive film at a plurality of second locations adapted to interact with the first conductors to excite one or more selected micro-components. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
-
-
15. A method for forming a flexible light emitting panel comprising:
-
feeding a first substrate material from a payout reel into a web coating machine;
printing a first plurality of electrodes on the first substrate material;
forming a plurality of sockets at a plurality of locations in the first substrate material;
disposing at least one micro-component in each socket of the plurality of sockets;
applying a first dielectric material over the first substrate material, the first plurality of electrodes, and at least a portion of each micro-component of the plurality of micro-components; and
printing a second plurality of electrodes over the first dielectric material. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
-
-
26. A method for forming a flexible light emitting panel comprising:
-
feeding a first dielectric substrate material from a payout reel in a web coating machine;
printing a first plurality of electrodes on the first dielectric material;
forming a plurality of sockets at a plurality of locations in the first dielectric material;
disposing at least one micro-component in each socket of the plurality of sockets;
aligning a second sheet of material over the first dielectric substrate material and the first plurality of electrodes, wherein the second dielectric sheet material has a plurality of openings therein corresponding to the plurality of locations, the plurality of openings having diameters sized to allow the at least one micro-component to pass therethrough;
applying a dielectric material over at least a portion of the second sheet material; and
printing a second plurality of electrodes over the second sheet material.
-
Specification