Design, fabrication, testing, and conditioning of micro-components for use in a light-emitting panel

• US 7,288,014 B1
• Filed: 01/14/2004
• Issued: 10/30/2007
• Est. Priority Date: 10/27/2000
• Status: Expired due to Fees

• Current Assignee: Leidos, Inc. (Leidos Holdings, Inc.)
• Original Assignee: Science Applications International Corporation
• Inventors: Green, Albert Myron, George, Edward Victor, Wyeth, Newell Convers
• Primary Examiner(s): Schillinger; Laura M.
• Application Number:
  US10/756,266
• Time in Patent Office: 1,385 Days
• Field of Search: 313/582, 445/24, 438/30
• US Class Current: 445/24
• CPC Class Codes: G02B 6/0033 Means for improving the coupling-out of light from the light guide
• CPC Class Codes: G02B 6/0036 2-D arrangement of prisms, protrusions, indentations or roughened surfaces
• CPC Class Codes: G02B 6/0065 Manufacturing aspects; Material aspects

Abstract

A method of forming micro-components is disclosed. The method includes pretesting and conditioning of the micro-components. The micro-components that fail testing or conditioning are discarded, and those remaining are assembled into a panel.

Claims

1. A process for forming a light-emitting micro-component, comprising:

forming a shell of predetermined shape and encapsulating therein a plasma-forming gas to thereby form a micro-component; and

texturing a portion of the micro-component to form a texturized portion, wherein upon application of an electrical signal, the micro-component is caused to emit light through the texturized portion.

2. The process of claim 1, wherein texturizing a portion of the micro-component is achieved by sandblasting the shell of the micro-component.

3. The process of claim 1, wherein texturizing a portion of the micro-component is achieved by etching the shell of the micro-component.

4. The process of claim 1, wherein texturizing a portion of the micro-component is achieved through lithography.

5. The process of claim 1, wherein the texturized portion is approximately 10 to 100 microns in diameter, depending on the diameter of the micro-component.

6. The process of claim 1, further comprising doping the shell of the micro-component with a rare earth material.

7. The process of claim 6, wherein the rare earth material is selected from the group consisting of europium 2+ for blue, europium 3+ for red, cerium 3+ for violet, and cerium 3+ plus terbium 3+ for green.

8. The process of claim 1, wherein the plasma-forming gas is a rare gas halide mixture.