US 2004/0166762 A1 · Liquid maufacturing processes for panel layer fabrication

Abstract

A method for manufacturing a light-emitting panel sandwiches a plurality of micro-components between two flexible substrates in a web configuration. Each micro-component contains a gas or gas-mixture capable of ionization when a sufficiently large voltage is supplied across the micro-component via at least two electrodes. The micro-components are disposed in sockets formed at pre-determined locations in a first dielectric substrate so that they are adjacent to electrodes imprinted in the first substrate. Dielectric layers and the conductors for acting as electrodes are formed using liquid processes or combined liquid and sheet processes, where liquid materials are applied to the surface of the underlying layer, then cured to complete the formation of layers. The assembled layers are coated with a protective coating and may include an RF shield. In one embodiment, patterning of the conductors is achieved by applying conductive ink using an ink jet process. In another embodiment, the conductors may be patterned photolithographically using a leaky optical waveguide as a contact mask.

Claims35

Dependent claims

A method for manufacturing a light-emitting panel in a web configuration comprising:

(a) providing a first substrate in a web form, the first substrate having a plurality of first conductors formed thereon;
(b) disposing at least one micro-component of a plurality of micro-components at each of a plurality of first locations on the first substrate corresponding to the plurality of conductors, each micro-component adapted to emit radiation in response to electrical excitation;
(c) depositing a liquid dielectric material onto the first substrate to electrically isolate the plurality of micro-components from each other;
(d) curing the liquid dielectric material to form a dielectric layer;
(e) depositing a conductive liquid on top of the dielectric layer at a plurality of second locations adapted to interact with the first conductors to excite one or more selected micro-components;
(f) curing the conductive liquid to create a conductive film for providing second conductors;
(g) applying a top layer over the dielectric layer and the second conductors.

4 more elements

A method for forming a flexible light emitting panel comprising:

(a) feeding a first dielectric substrate material from a payout reel in a web coating machine;
(b) printing a first plurality of electrodes on the first dielectric material;
(c) before or after printing the first plurality of electrodes, forming a plurality of sockets at a plurality of location in the first dielectric material;
(d) disposing at least one micro-component in each socket of the plurality of sockets, wherein the at least one micro-component is adapted to emit light in response to electrical excitation;
(e) aligning a second sheet material having dielectric properties over the first dielectric substrate material and the first plurality of electrodes, wherein the second dielectric sheet material has a plurality of openings therethrough corresponding to the plurality of locations, the plurality of openings having diameters larger than an outer diameter of the micro-component;
so that a gap is created between an inner diameter of each opening and the outer diameter of each micro-component;
(f) applying a liquid dielectric material over at least a portion of the second sheet material so that the gap corresponding to each micro-component is filled, the liquid dielectric material having dielectric properties adapted for control of electric field and breakdown characteristics of the micro-component;
(g) curing the liquid dielectric material;
(h) printing a second plurality of electrodes over the second sheet material using a conductive ink;
(i) curing the conductive ink;
(j) applying a top layer over the second sheet material, the second plurality of electrodes and the micro-components.

8 more elements

Dependencies are inferred from the claim text.

Liquid maufacturing processes for panel layer fabrication

Life of this patent

Liquid maufacturing processes for panel layer fabrication

Life of this patent

Abstract

Claims35