Optics formation using pick-up tools

Patent metadata

Field	Value
Publication number	US-2020035882-A1
Application number	US-201816049728-A
Country	US
Kind code	A1
Filing date	Jul 30, 2018
Priority date	Jul 30, 2018
Publication date	Jan 30, 2020
Grant date	—

Abstract

Techniques related to optics formation using pick-up tools are disclosed. Optical elements are formed by pressing a pick-up tool (PUT) against elastomeric material deposited on a light-outputting side of light-emitting diode (LED) devices. Pressing the PUT against the elastomeric material causes a molded shape of the PUT to be transferred to the elastomeric material. This forms the optical elements in the elastomeric material.

First claim

1 . A method comprising:
obtaining a set of one or more light-emitting diode (LED) devices having one or more elastomeric interfaces deposited on a light-outputting side of the set of one or more LED devices; using a pick-up tool to:
form one or more optical elements in the one or more elastomeric interfaces by pressing the pick-up tool against the one or more elastomeric interfaces; and
pick up and place the set of one or more LED devices onto a target substrate;
separating the pick-up tool from the one or more elastomeric interfaces, thereby revealing the one or more optical elements formed on the set of one or more LED devices.

2 . The method of claim 1 , wherein the one or more optical elements are formed in the one or more elastomeric interfaces before the set of one or more LED devices is picked up and placed onto the target substrate.

3 . The method of claim 1 , wherein the one or more optical elements are formed in the one or more elastomeric interfaces after the set of one or more LED devices is picked up but as the set of one or more LED devices is being placed onto the target substrate.

4 . (canceled)

5 . The method of claim 1 , further comprising:
removing, from the one or more elastomeric interfaces, elastomeric material surrounding the one or more optical elements.

6 . The method of claim 1 , wherein the set of one or more LED devices comprises a plurality of unsingulated LED devices.

7 . The method of claim 1 , wherein the set of one or more optical elements includes at least one of a group comprising a lens, a waveguide, and a diffraction grating.

8 . The method of claim 1 , wherein obtaining the set of one or more LED devices having the one or more elastomeric interfaces comprises:
obtaining a layered structure that includes an embedded layer comprising multiple sets of one or more LED devices embedded in a filling material, an elastomeric layer deposited on the embedded layer, and a photoresist layer deposited on the elastomeric layer; patterning the photoresist layer by using the multiple sets of one or more LED devices as a mask in a first direction; patterning the elastomeric layer using the patterned photoresist layer as a mask in a second direction that is opposite the first direction; after patterning the elastomeric layer, removing the filling material and the patterned photoresist layer, thereby revealing the multiple sets of one or more LED devices having the patterned elastomeric layer deposited thereon.

9 . The method of claim 8 , wherein patterning the photoresist layer comprises transmitting light through the elastomeric layer toward the photoresist layer.

10 . The method of claim 8 , wherein patterning the elastomeric layer comprises etching the elastomeric layer.

11 . A display system fabricated by a method comprising:
obtaining a set of one or more light-emitting diode (LED) devices having one or more elastomeric interfaces deposited on a light-outputting side of the set of one or more LED devices; using a pick-up tool to:
form one or more optical elements in the one or more elastomeric interfaces by pressing the pick-up tool against the one or more elastomeric interfaces; and
pick up and place the set of one or more LED devices onto a target substrate;
separating the pick-up tool from the one or more elastomeric interfaces, thereby revealing the one or more optical elements formed on the set of one or more LED devices.

12 . The display system of claim 11 , wherein the one or more optical elements are formed in the one or more elastomeric interfaces before the set of one or more LED devices is picked up and placed onto the target substrate.

13 . The display system of claim 11 , wherein the one or more optical elements are formed in the one or more elastomeric interfaces after the set of one or more LED devices is picked up but as the set of one or more LED devices is being placed onto the target substrate.

14 . The display system of claim 11 fabricated by the method, the method further comprising:
removing, from the one or more elastomeric interfaces, elastomeric material surrounding the one or more optical elements.

15 . The display system of claim 11 , wherein the set of one or more LED devices comprises a plurality of unsingulated LED devices.

16 . The display system of claim 11 , wherein the set of one or more optical elements includes at least one of a group comprising a lens, a waveguide, and a diffraction grating.

17 . The display system of claim 11 , wherein obtaining the set of one or more LED devices having the one or more elastomeric interfaces comprises:
obtaining a layered structure that includes an embedded layer comprising multiple sets of one or more LED devices embedded in a filling material, an elastomeric layer deposited on the embedded layer, and a photoresist layer deposited on the elastomeric layer; patterning the photoresist layer by using the multiple sets of one or more LED devices as a mask in a first direction; patterning the elastomeric layer using the patterned photoresist layer as a mask in a second direction that is opposite the first direction; after patterning the elastomeric layer, removing the filling material and the patterned photoresist layer, thereby revealing the multiple sets of one or more LED devices having the patterned elastomeric layer deposited thereon.

18 . A non-transitory computer-readable storage medium storing processor-executable instructions for:
obtaining a set of one or more light-emitting diode (LED) devices having one or more elastomeric interfaces deposited on a light-outputting side of the set of one or more LED devices; using a pick-up tool to:
form one or more optical elements in the one or more elastomeric interfaces by pressing the pick-up tool against the one or more elastomeric interfaces; and
pick up and place the set of one or more LED devices onto a target substrate;
separating the pick-up tool from the one or more elastomeric interfaces, thereby revealing the one or more optical elements formed on the set of one or more LED devices.

19 . The non-transitory computer-readable storage medium of claim 18 , wherein the one or more optical elements are formed in the one or more elastomeric interfaces before the set of one or more LED devices is picked up and placed onto the target substrate.

20 . The non-transitory computer-readable storage medium of claim 18 , wherein the one or more optical elements are formed in the one or more elastomeric interfaces after the set of one or more LED devices is picked up but as the set of one or more LED devices is being placed onto the target substrate.

Assignees

• Facebook Tech Llc

Inventors

• Brodoceanu Daniel
• Hughes Patrick Joseph
• Saketi Pooya
• Torrents Abad Oscar

Classifications

• H10P72/0446

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• H10W90/00

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• B29D11/00807

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• B29D11/00365 Primary

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• B29D11/00298

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