Method for microperturbation assembly

Patent metadata

Field	Value
Publication number	US-11278900-B2
Application number	US-202016737353-A
Country	US
Kind code	B2
Filing date	Jan 8, 2020
Priority date	Oct 31, 2014
Publication date	Mar 22, 2022
Grant date	Mar 22, 2022

Abstract

Microperturbation fluidic assembly systems and methods are provided for the fabrication of emissive panels. The method provides an emissive substrate with a top surface patterned to form an array of wells. A liquid suspension is formed over the emissive substrate top surface, comprising a first liquid and emissive elements. Using an array of micropores, a perturbation medium, which optionally includes emissive elements, is injected into the liquid suspension. The perturbation medium may be the first liquid, a second liquid, or a gas. A laminar flow is created in the liquid suspension along the top surface of the emissive substrate in response to the perturbation medium, and emissive elements are captured in the wells. The ejection of the perturbation medium can also be used to control the thickness of the liquid suspension overlying the top surface of the emissive substrate.

First claim

We claim:

1. A microperturbation fluidic assembly method for the fabrication of emissive panels, the method comprising:
providing an emissive substrate with a top surface patterned to form an array of wells;
supplying a liquid suspension, comprising a first liquid and emissive elements, overlying the emissive substrate top surface;
locating an array of micropores a predetermined distance above a top surface of the liquid suspension and ejecting a perturbation medium selected from the group consisting of the first liquid, a second liquid, and a gas, into the liquid suspension;
in response to the perturbation medium, creating a laminar flow in the liquid suspension along the top surface of the emissive substrate; and,
in response to the laminar flow, capturing the emissive elements in the wells.

2. The method of claim 1 wherein ejecting the selected perturbation medium from the micropores includes ejecting a selected liquid medium in response to a force selected from the group consisting of gravity and a positive pressure.

3. The method of claim 1 further comprising:
simultaneously with creating the laminar flow in the liquid suspension, controlling the thickness of the liquid suspension overlying the top surface of the emissive substrate in response to ejecting the selected perturbation medium.

4. The method of claim 1 wherein supplying the liquid suspension includes supplying the liquid suspension with the first liquid having a first temperature; and,
wherein ejecting the perturbation medium includes ejecting a selected perturbation medium having a second temperature, greater than the first temperature.

5. The method of claim 1 wherein ejecting the perturbation medium includes periodically ejecting the perturbation medium, creating a pulsed ejection having a frequency in a range of 0.5 to 100 Hertz.

6. The method of claim 1 further comprising:
synchronously with the ejection of the perturbation medium, moving the array of micropores in a predetermined pattern with respect to the emissive substrate top surface.

7. The method of claim 1 further comprising:
subsequent to capturing the emissive elements in the wells, removing the liquid suspension from the emissive substrate using a process selected from the group consisting of:
heating the emissive substrate; and
using the array of micropores to reduce the thickness of the liquid suspension overlying emissive substrate.

8. The method of claim 1 wherein creating the laminar flow includes creating the laminar flow in response to characteristics selected from the group consisting of pitch between micropores, micropore diameters, array material, perturbation medium ejection rate, perturbation medium ejection pressure, first fluid viscosity, first fluid density, liquid perturbation medium viscosity, liquid perturbation medium density, and combinations thereof.

9. The method of claim 1 wherein ejecting the perturbation medium includes ejecting a perturbation medium additionally comprising emissive elements.

10. The method of claim 1 further comprising:
subsequent to capturing the emissive elements in the well, ejecting perturbation medium from a detrapping nozzle to dislodge misaligned and damaged emissive elements from the wells.

11. The method of claim 1 wherein ejecting the perturbation medium into the liquid suspension includes:
initially ejecting the perturbation medium at a first pressure to distribute the emissive elements across the top surface of the emissive substrate;
subsequently ejecting the perturbation medium at a second pressure, less than the first pressure; and,
wherein creating the laminar flow includes creating the laminar flow in response to the second pressure.

12. The method of claim 11 wherein supplying the liquid suspension includes supplying a liquid suspension comprising emissive elements with orientation posts;
wherein initially ejecting the perturbation medium at the first pressure includes:
orienting the emissive elements in a post-up orientation in response to the orientation posts and the first pressure; and,
removing misoriented emissive elements.

13. The method of claim 1 wherein using the array of micropores includes using an interleaved array comprising a first group of micropores ejecting perturbation medium and a second group of micropores aspirating liquid suspension.

14. The method of claim 1 wherein using the array of micropores includes using an interleaved array comprising a first group of micropores ejecting a liquid perturbation medium and a second group of micropores ejecting a gaseous perturbation medium.

15. A microperturbation fluidic assembly method for the fabrication of emissive panels, the method comprising:
providing an emissive substrate with a top surface patterned to form an array of wells;
supplying a liquid suspension, comprising a first liquid and emissive elements, overlying the emissive substrate top surface, with the first liquid having a first temperature;
using an array of micropores, ejecting a perturbation medium into the liquid suspension, where the perturbation medium has a second temperature greater than the first temperature;
in response to the perturbation medium, creating a laminar flow in the liquid suspension along the top surface of the emissive substrate; and,
in response to the laminar flow, capturing the emissive elements in the wells.

16. The method of claim 15 further comprising:
simultaneously with creating the laminar flow in the liquid suspension, controlling the thickness of the liquid suspension overlying the top surface of the emissive substrate in response to ejecting the selected perturbation medium.

17. The method of claim 15 further comprising:
synchronously with the ejection of the perturbation medium, moving the array of micropores in a predetermined pattern with respect to the emissive substrate top surface.

18. The method of claim 15 wherein creating the laminar flow includes creating the laminar flow in response to characteristics selected from the group consisting of pitch between micropores, micropore diameters, array material, perturbation medium ejection rate, perturbation medium ejection pressure, first fluid viscosity, first fluid density, liquid perturbation medium viscosity, liquid perturbation medium density, and combinations thereof.

19. A microperturbation fluidic assembly method for the fabrication of emissive panels, the method comprising:
providing an emissive substrate with a top surface patterned to form an array of wells;
supplying a liquid suspension, comprising a first liquid and emissive elements, overlying the emissive substrate top surface;
using an interleaved array of micropores, ejecting a perturbation medium into the liquid suspension, where the interleaved array comprises a first group of micropores ejecting perturbation medium and a second group of micropores aspirating liquid suspension;
in response to the perturbation medium, creating a laminar flow in the liquid suspension along the top surface of the emissive substrate; and,
in response to the laminar flow, capturing the emissive elements in the wells.

20. The method of claim 19 wherein using the array of micropores includes submerging the array of micropores in the liquid suspension.

21. The method of claim 19 further comprising:
simultaneously with creating the laminar flow in the liquid suspension, controlling the thickness of the liquid suspension overlying the top surface of the emissive substrate in response to

Assignees

• Elux Inc

Inventors

• Sasaki Kenji
• Yu Shu-Han
• Schuele Paul J

Classifications

• H10W72/9413

  on encapsulations · CPC title

• H10W72/874

  On different surfaces · CPC title

• H10W72/0198

  batch processes · CPC title

• H10W70/682

  comprising holes having chips therein · CPC title

• H10W90/00 Primary

  Package configurations · CPC title