Substrate with topological features for steering fluidic assembly LED disks

• US 9,755,110 B1
• Filed: 07/27/2016
• Issued: 09/05/2017
• Est. Priority Date: 07/27/2016
• Status: Active Grant

• Current Assignee: Elux Inc.
• Original Assignee: Sharp Laboratories of America Incorporated (Hon Hai Precision Industry Co., Ltd.)
• Inventors: Crowder, Mark Albert, Schuele, Paul J., Zhan, Changqing, Sasaki, Kenji Alexander, Ulmer, Kurt Michael
• Primary Examiner(s): Jahan, Bilkis
• Application Number:
  US15/221,571
• Time in Patent Office: 405 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 fluidic assembly direct-emission display panel comprising:

a substrate with a planar top surface and interconnect pads aligned in a plurality of rows;

a first film disposed over the top surface of the substrate, wherein the first film includes a plurality of wells, and wherein each of the plurality of wells exposes a corresponding ones of the interconnect pads; and

a second film disposed over the first film, wherein the second film includes at least one steering feature surrounding two or more of the plurality of wells.

2. The panel of claim 1, wherein the 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.

3. The panel of claim 2, wherein the two or more of the plurality of wells is part of a column of wells.

4. The panel of claim 1, wherein the second film is a removable material.

5. The panel of claim 1, wherein the two or more of the plurality of wells each have a perimeter;

and wherein the at least one steering feature in the second film 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.

6. The panel of claim 1, wherein the substrate further includes a plurality of bottom electrically conductive traces, with each bottom electrically conductive trace being associated with a corresponding one of the plurality of rows.

7. The panel of claim 6, 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.

8. The panel of claim 7, wherein the first film has a thickness;

wherein the LED disks have about the same thickness; and

wherein the panel further comprises;

an insulator material filling each steering feature, with vias exposing a top contact of each of the LED disks; and

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

9. The panel of claim 1, wherein the substrate includes a through-hole via (THV) co-located with each of the interconnect pads.

10. The panel of claim 7, wherein the substrate includes a through-hole via (THV) co-located with each of the interconnect pads, and wherein a cross-sectional opening of the THV is less than a width of each of the LED disks.

11. A display panel, the panel comprising:

a substrate with a planar top surface and interconnect pads;

a first film layer disposed over the top surface of the substrate, wherein the first film layer includes a plurality of wells, and wherein each of the plurality of wells exposes a corresponding ones of the interconnect pads; and

a second film layer disposed over the first film layer, wherein the second film layer includes at least one steering structure surrounding two or more of the plurality of wells.