Self assembly of elements for displays

• US 9,153,163 B2
• Filed: 03/11/2005
• Issued: 10/06/2015
• Est. Priority Date: 03/11/2005
• Status: Expired due to Fees

• Current Assignee: Enterprise Science Fund, LLC (Intellectual Ventures LLC)
• Original Assignee: The Invention Science Fund I, L.L.C. (Intellectual Ventures LLC)
• Inventors: Hillis, W. Daniel, Myhrvold, Nathan P., Tegreene, Clarence T., Wood, Lowell L. Jr., Wood, Victoria Y. H.
• Primary Examiner(s): Pervan, Michael
• Application Number:
  US11/078,206
• Publication Number:
  US 20060202943A1
• Time in Patent Office: 3,861 Days
• Field of Search: 445/24, 349/45, 438/4, 438 14- 17, 438 22- 47, 257/88, 257/89, 977/883
• US Class Current: 1/1
• CPC Class Codes: G09G 2300/0452 Details of colour pixel setup, e.g. pixel composed of a red, a blue and two green components
• CPC Class Codes: G09G 2330/10 Dealing with defective pixels
• CPC Class Codes: G09G 3/03 specially adapted for displays having non-planar surfaces, e.g. curved displays
• CPC Class Codes: G09G 3/035 for flexible display surfaces
• CPC Class Codes: G09G 3/20 for presentation of an assembly of a number of characters, e.g. a page, by composing the assembly by combination of individual elements arranged in a matrix no fixed position being assigned to or needed to be assigned to the individual characters or partial characters
• CPC Class Codes: G09G 3/2085 Special arrangements for addressing the individual elements of the matrix, other than by driving respective rows and columns in combination
• CPC Class Codes: G09G 3/2088 with use of a plurality of processors, each processor controlling a number of individual elements of the matrix
• CPC Class Codes: H01L 2224/95085 being a liquid, e.g. for fluidic self-assembly
• CPC Class Codes: H01L 2224/95145 Electrostatic alignment, i.e. polarity alignment with Coulomb charges
• CPC Class Codes: H01L 24/95 at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips
• CPC Class Codes: H01L 25/50 Multistep manufacturing processes of assemblies consisting of devices, each device being of a type provided for in group H01L27/00 or H01L29/00 H01L21/50 takes precedence
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/01005 Boron [B]
• CPC Class Codes: H01L 2924/01006 Carbon [C]
• CPC Class Codes: H01L 2924/01013 Aluminum [Al]
• CPC Class Codes: H01L 2924/01033 Arsenic [As]
• CPC Class Codes: H01L 2924/01074 Tungsten [W]
• CPC Class Codes: H01L 2924/01075 Rhenium [Re]
• CPC Class Codes: H01L 2924/01082 Lead [Pb]
• CPC Class Codes: H01L 2924/12041 LED
• CPC Class Codes: H01L 2924/12044 : OLED
• CPC Class Codes: H01L 2924/14 : Integrated circuits
• CPC Class Codes: H01L 2924/1433 : Application-specific integrated circuit [ASIC]

Abstract

Various embodiments of methods and systems for designing and constructing displays from multiple light emitting elements are disclosed. Display elements having different light emitting and self-organizing characteristics may be used during display assembly.

Claims

1. A method of forming a display, comprising:

a) disposing a plurality of display elements of a plurality of types onto a substrate, each of said plurality of types of display elements being configured to form preferred associations with one or more other types of display elements with a degree of preference that depends upon the type of display element, each preferred association promoted by an interaction between a first at least one surface or shape property of one display element of said plurality of types of display elements and a second at least one surface or shape property of another display element of said plurality of types of display elements;

b) inducing relative movement of display elements and said surface sufficient to produce association of at least a portion of said display elements with other said display elements to form a group of associated display elements, wherein said induced movement is sufficient to permit said display elements to self-organize to form preferred associations within said group of associated display elements; and

c) connecting said group of associated display elements in fixed relationship to each other.

2. The method of claim 1, wherein disposing a plurality of display elements of a plurality of types onto a substrate includes disposing a first plurality of display elements onto said substrate and disposing a second plurality of display elements onto said substrate.

3. The method of claim 2, wherein said first plurality of types includes one or more display element types that differ from display element types in said second plurality of types by one or more characteristics including display element size, wavelength band envelope, spectral width, power, emission pattern, polarity, response speed, or linearity.

4. The method of claim 1, wherein each of said types of display elements in said plurality of types has a characteristic comprising at least one of a characteristic shape or characteristic surface property adapted for forming preferred associations with one or more other types of display elements with a degree of preference that depends upon the type of display element.

5. The method of claim 4, wherein each of said types of display elements in said plurality of types has a characteristic comprising at least one of a characteristic shape or characteristic surface property selected to provide a relatively lower preference for said display element forming associations with other display elements of the same type than for forming associations with other display elements of a different type.

6. The method of claim 1, including:

a) testing at least a portion of said group of associated display elements to detect at least one defective display element; and

b) removing at least one defective display elements.

7. The method of claim 6, including replacing at least a portion of said one or more defective display elements with one or more replacement display elements.

8. The method of claim 7, including replacing said at least a portion of said one or more defective display elements by picking and placing said one or more replacement display elements.

9. The method of claim 7, including replacing said at least a portion of said one or more defective display elements by disposing a plurality of replacement display elements on at least a region of said substrate from which said one or more defective display elements were removed and inducing relative movement sufficient to cause said replacement display elements to move into preferred associations within said group of associated display elements.

10. The method of claim 1, wherein said elements distribute into a single layer on said substrate, aided by at least one of gravity, attraction of at least one surface of each said element to said substrate, or repulsion of at least one surface of each said element from said substrate.

11. The method of claim 1, including connecting said group of associated display elements to each other by at least one of heat, vibration, pressure, chemical treatment, or an adhesive.

12. The method of claim 11, comprising removing said connected group of associated display elements from said substrate as a unit.

13. A multi-element display comprising a plurality of display elements in a self-organized array, said plurality of display elements comprising two or more types of display elements self-organized by type into a preferred arrangement in which the position of display elements of each type relative to display elements of other types is specified;

wherein display elements of each type are characterized by at least one surface or shape property that promotes interaction between the at least one surface or shape property and another at least one surface or shape property of other display elements to form said preferred arrangement.

14. The multi-element display of claim 13, wherein each display element type differs from at least one other display element type by one or more characteristics including size, shape, wavelength band envelope, spectral width, power, emission pattern, polarity, response speed, or linearity.

15. The multi-element display of claim 13, wherein display elements of each type are characterized by a combination of characteristic shape and characteristic surface property adapted for forming preferred associations with one or more other types of display element with a degree of preference that depends upon the type of display element.

16. The multi-element display of claim 13, configured as at least one of a television screen, a computer monitor, a video screen, a sign, a decorative item, an item of apparel, a decorative pattern region on an item of manufacture, or a functional pattern region on an item of manufacture.

17. The multi-element display of claim 13, including at least one spacer element located between two or more of said display elements.

18. The multi-element display of claim 13, wherein each said display element type has a light spectral characteristic comprising at least one of a light absorption spectrum, a light emission spectrum, or a light reflection spectrum.

19. The multi-element display of claim 13, wherein said at least one surface or shape property comprises at least one of a surface charge, a surface energy, a magnetic property, a binding affinity of a biomolecule, a concavity, or a convexity.

20. A multi-color display comprising a plurality of display elements in a self-organized array;

wherein said plurality of display elements is comprised of two or more colors of display elements self-organized by color so that each said display element has at least one nearest neighbor that is of a different color;

wherein display elements of each color are characterized by at least one surface or shape property that promotes interaction between said at least one surface or shape property and another at least one surface or shape property of another display element of a different color and inhibits association of display elements with other display elements of the same said color.

21. The multi-color display of claim 20, wherein each said display element comprises at least one of an organic or inorganic wavelength converter, a light emitting element, a light absorbing element, or a light reflecting element.

22. The multi-color display of claim 20, wherein said at least one surface or shape property comprises a surface charge or a magnetic characteristic.

23. The multi-color display of claim 20, wherein each said display element comprises one or more of a contact for forming an electrical or optical connection with a substrate or another display element, a radio receiver, or a radio transmitter.