US 12,080,690 B2
Micro assembled LED displays and lighting elements
Christopher Bower, Raleigh, NC (US); Matthew Meitl, Durham, NC (US); David Gomez, Holly Springs, NC (US); Salvatore Bonafede, Chapel Hill, NC (US); David Kneeburg, Durham, NC (US); Alin Fecioru, Cork (IE); and Carl Prevatte, Raleigh, NC (US)
Assigned to X Display Company Technology Limited, Dublin (IE)
Filed by X Display Company Technology Limited, Dublin (IE)
Filed on Nov. 13, 2023, as Appl. No. 18/507,597.
Application 18/507,597 is a continuation of application No. 17/203,314, filed on Mar. 16, 2021, granted, now 11,854,788.
Application 17/203,314 is a continuation of application No. 16/244,860, filed on Jan. 10, 2019, granted, now 10,985,143, issued on Apr. 20, 2021.
Application 16/244,860 is a continuation of application No. 14/743,788, filed on Jun. 18, 2015, granted, now 10,224,460, issued on Mar. 5, 2019.
Claims priority of provisional application 62/169,531, filed on Jun. 1, 2015.
Claims priority of provisional application 62/148,603, filed on Apr. 16, 2015.
Claims priority of provisional application 62/131,230, filed on Mar. 10, 2015.
Claims priority of provisional application 62/056,419, filed on Sep. 26, 2014.
Claims priority of provisional application 62/055,485, filed on Sep. 25, 2014.
Claims priority of provisional application 62/029,533, filed on Jul. 27, 2014.
Claims priority of provisional application 62/026,695, filed on Jul. 20, 2014.
Claims priority of provisional application 62/014,077, filed on Jun. 18, 2014.
Prior Publication US 2024/0153927 A1, May 9, 2024
Int. Cl. H01L 25/075 (2006.01); F21V 9/08 (2018.01); G02B 26/04 (2006.01); G02F 1/167 (2019.01); G09G 3/22 (2006.01); G09G 3/32 (2016.01); H01L 23/482 (2006.01); H01L 23/538 (2006.01); H01L 25/16 (2023.01); H01L 27/15 (2006.01); H01L 33/36 (2010.01); H01L 33/38 (2010.01); H01L 33/48 (2010.01); H01L 33/50 (2010.01); H01L 33/58 (2010.01); H01L 33/60 (2010.01); H01L 33/62 (2010.01); H05K 1/03 (2006.01); H05K 1/09 (2006.01); H05K 1/18 (2006.01); H05K 5/00 (2006.01); F21Y 105/10 (2016.01); F21Y 113/13 (2016.01); F21Y 115/10 (2016.01); H01L 33/20 (2010.01); H01L 33/40 (2010.01)
CPC H01L 25/0753 (2013.01) [F21V 9/08 (2013.01); G02B 26/04 (2013.01); G02F 1/167 (2013.01); G09G 3/22 (2013.01); G09G 3/32 (2013.01); H01L 23/4821 (2013.01); H01L 23/5381 (2013.01); H01L 25/167 (2013.01); H01L 27/156 (2013.01); H01L 33/36 (2013.01); H01L 33/38 (2013.01); H01L 33/385 (2013.01); H01L 33/48 (2013.01); H01L 33/50 (2013.01); H01L 33/502 (2013.01); H01L 33/508 (2013.01); H01L 33/58 (2013.01); H01L 33/60 (2013.01); H01L 33/62 (2013.01); H05K 1/0306 (2013.01); H05K 1/09 (2013.01); H05K 1/181 (2013.01); H05K 1/182 (2013.01); H05K 5/0017 (2013.01); F21Y 2105/10 (2016.08); F21Y 2113/13 (2016.08); F21Y 2115/10 (2016.08); G09G 2300/0452 (2013.01); G09G 2300/0842 (2013.01); G09G 2310/0264 (2013.01); H01L 33/20 (2013.01); H01L 33/405 (2013.01); H01L 2224/18 (2013.01); H01L 2224/73267 (2013.01); H01L 2224/92244 (2013.01); H05K 2201/0329 (2013.01); H05K 2201/10106 (2013.01); H05K 2201/10128 (2013.01); H05K 2201/10166 (2013.01)] 27 Claims
OG exemplary drawing
 
1. A method of forming a display, the method comprising:
depositing a first metal layer on and in direct contact with a surface of a display substrate;
patterning the first metal layer to form a first patterned metal layer;
depositing a layer of dielectric on and in direct contact with the first patterned metal layer to create an electrically insulating layer;
applying an uncured polymer layer on and in direct contact with the dielectric layer, the uncured polymer layer comprising a material different from the dielectric layer;
micro-transfer printing a plurality of light emitters from a native substrate onto and in direct contact with a surface of the uncured polymer layer, wherein the native substrate is native to at least a portion of the plurality of light emitters and the light emitters each have an anode and a cathode for providing power to the light emitters;
exposing the polymer to ultraviolet light to cure the polymer;
forming a plurality of vias through the cured polymer and dielectric layer to expose a portion of the first patterned metal layer;
depositing a second metal layer, wherein the second metal layer contacts an anode and a cathode of each light emitter of the plurality of light emitters; and
patterning the second metal layer to form the second patterned metal layer, wherein the second patterned metal layer comprises a plurality of anode interconnections and a plurality of cathode interconnections, each anode interconnection electrically connecting the anode of a corresponding light emitter of the plurality of light emitters to the first patterned metal layer through a corresponding via of the plurality of vias and each cathode interconnection electrically contacting the cathode of a corresponding light emitter of the plurality of light emitters.