Method for testing a light-emitting panel and the components therein
AssigneeScience Applications International Corporation
InventorsRoger Laverne Johnson, Albert Myron Green, Edward Victor George, Newell Convers Wyeth
Life of this patent
Estimating the term…
Abstract
An improved light-emitting panel having a plurality of micro-components sandwiched between two substrates is disclosed. 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. A method of testing a light-emitting panel and the component parts therein is also disclosed, which uses a web fabrication process to manufacturing light-emitting panels combined with inline testing after the various process steps of the manufacturing process to produce result which are used to adjust the various process steps and component parts.
Claims29
A method for inline testing a plurality of light-emitting panels, comprising the steps of:
- manufacturing the plurality of light-emitting panels in a web fabrication process, the web fabrication process comprising a plurality of process steps and a plurality of component parts, wherein the plurality of process steps are performed a plurality of times to manufacture the plurality of light-emitting panels, and further wherein the plurality of process steps comprise a micro-component forming process, a socket formation process, an electrode placement process a micro-component placement process, an alignment process, and a panel dicing process;
- testing a portion of one or more light-emitting panels after at least one process step of the plurality of process steps is performed at least one time;
- processing data from the testing to produce at least one result;
- analyzing the at least one result to determine whether the at least one result is within a specific target range;
- and
- adjusting the at least one process step or at least one component part of the plurality of component parts if the at least one result is not within the specific target range.
A method for inline testing a plurality of light-emitting panels, comprising the steps of:
- manufacturing the plurality of light-emitting panels in a web fabrication process, the web fabrication process comprising a plurality of process steps and a plurality of component parts, wherein the plurality of process steps are performed a plurality of times to manufacture the plurality of light-emitting panels;
- testing a portion of one or more light-emitting panels after at least one process step of the plurality of process steps is performed at least one time;
- processing data from the testing to produce at least one result;
- analyzing the at least one result to determine whether the at least one result is within a specific target range;
- and
- adjusting the at least one process step or at least one component part of the plurality of component parts if the at least one result is not within the specific target range,
- wherein the step of testing the portion of one or more light-emitting panels, comprises the step of testing more than one light emitting panel, wherein the step of processing data, comprises the step of storing the at least one result after each time a light-emitting panel is tested to produce a plurality of stored results, wherein the step of analyzing the at least one result, comprises the step of analyzing the plurality of stored results to determine whether there is consistent nonconformity, and wherein the step of adjusting the at least one process step or the at least one component part, comprises the step of adjusting the at least one process step or the at least one component part if there is consistent nonconformity.
A method for forming a light-emitting panel, comprising the steps of:
- providing a first substrate;
- forming a plurality of cavities on or within the first substrate;
- placing at least one micro-component in each cavity;
- providing a second substrate opposed to the first substrate such that the at least one micro-component is sandwiched between the first substrate and the second substrate;
- disposing at least two electrodes so that voltage supplied to the at least two electrodes causes one or more micro-components to emit radiation;
- and
- inline testing the first substrate, at least one cavity, at least one micro-component, at least one electrode, and optionally the second substrate.
Dependencies are inferred from the claim text.