U.S. patent application number 10/979214 was filed with the patent office on 2005-05-05 for design, fabrication, testing, and conditioning of micro-components for use in a light-emitting panel.
This patent application is currently assigned to Science Applications International Corporation. Invention is credited to Drobot, Adam T., George, E. Victor, Green, Albert M., Wyeth, N. Convers.
Application Number | 20050095944 10/979214 |
Document ID | / |
Family ID | 31714257 |
Filed Date | 2005-05-05 |
United States Patent
Application |
20050095944 |
Kind Code |
A1 |
George, E. Victor ; et
al. |
May 5, 2005 |
Design, fabrication, testing, and conditioning of micro-components
for use in a light-emitting panel
Abstract
A method of forming micro-components is disclosed. The method
includes pretesting and conditioning of the micro-components. The
micro-components that fail testing or conditioning are discarded,
and those remaining are assembled into a panel.
Inventors: |
George, E. Victor;
(Temecula, CA) ; Wyeth, N. Convers; (Oakton,
VA) ; Green, Albert M.; (Springfield, VA) ;
Drobot, Adam T.; (Vienna, VA) |
Correspondence
Address: |
KILPATRICK STOCKTON LLP
607 14TH STREET, N.W.
WASHINGTON
DC
20005
US
|
Assignee: |
Science Applications International
Corporation
|
Family ID: |
31714257 |
Appl. No.: |
10/979214 |
Filed: |
November 3, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10979214 |
Nov 3, 2004 |
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10214768 |
Aug 9, 2002 |
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6822626 |
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10214768 |
Aug 9, 2002 |
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09697358 |
Oct 27, 2000 |
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6762566 |
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Current U.S.
Class: |
445/3 ;
445/2 |
Current CPC
Class: |
G02B 6/0036 20130101;
G02B 6/0065 20130101; G02B 6/0033 20130101; H01J 9/241 20130101;
H01J 11/18 20130101; H01J 17/49 20130101; H01J 2217/49264
20130101 |
Class at
Publication: |
445/003 ;
445/002 |
International
Class: |
H01J 009/50; H01T
021/06 |
Claims
1-24. (canceled)
25. A process for forming a micro-component, comprising: forming a
shell of a predetermined shape; encapsulating a plasma-forming gas
within the shell to produce the micro-component; testing the
micro-component for a predetermined physical characteristic; and
discarding the micro-component if the micro-component does not meet
the predetermined physical characteristic.
26. The process of claim 25, further comprising: creating a liquid
droplet in the presence of a plasma-forming gas; encasing the
droplet with a material that forms the shell; and dehydrating the
droplet encased with the material.
27. The process of claim 25, wherein forming the shell comprises
forming the shell in the predetermined shape of a sphere.
28. The process of claim 25, wherein forming the shell comprises
forming the shell in the predetermined shape of a capillary.
29. The process of claim 25, wherein forming the shell comprises
glass blowing the shell with the plasma-forming gas.
30. The process of claim 25, wherein forming the shell comprises
forming the shell with an optical fiber extrusion device.
31. The process of claim 25, wherein testing comprises inspecting
the micro-component for a physical defect.
32. The process of claim 31, wherein discarding comprises
discarding the micro-component if the micro-component has the
physical defect.
33. The process of claim 25, wherein testing comprises exciting the
plasma-forming gas.
34. The process of claim 25, wherein testing comprises detecting a
luminous output from the micro-component.
35. The process of claim 34, wherein discarding the micro-component
comprises discarding the micro-component if the luminous output is
below a threshold level.
36. The process of claim 25, wherein the shell comprises two
openings and encapsulating the plasma-forming gas comprises
injecting the plasma-forming gas through one of the two openings
and sealing the two openings.
37. The process of claim 25, wherein forming the shell comprises
forming cavities in at least one of two substrates and
encapsulating comprises affixing the two substrates together in the
presence of the plasma-forming gas.
38. The process of claim 25, further comprising coating the
micro-component with a frequency converting coating.
39. The process of claim 38, wherein coating comprises coating the
micro-component with a rare earth material.
40. The process of claim 25, further comprising doping the shell
with a conductive material.
41. The process of claim 38, wherein coating comprises disposing
the conductive material in at least two localized areas on the
shell to provide conductive paths.
42. The process of claim 38, wherein coating comprises disposing
the conductive material in the shell to produce anisotropic
conductivity in the shell.
43. The process of claim 25, wherein encapsulating comprises
encapsulating a rare gas halide.
44. The process of claim 38, wherein the coating comprises coating
the shell with barium fluoride.
45. The process of claim 38, wherein coating comprises coating the
shell with yttrium aluminum garnet.
46. The process of claim 38, wherein coating comprises coating the
shell with yttrium aluminum garnet doped with cerium.
47. The process of claim 38, wherein coating comprises coating the
shell with gadolinium gallium garnet.
48. A process for testing a plurality of micro-components,
comprising: selecting each micro-component for testing during a
continuous process of manufacturing the micro-components; optically
inspecting each micro-component for a structural defect; and
discarding any micro-component having the structural defect.
49. The process of claim 48, further comprising applying an
excitation field to each micro-component to cause a plasma
generating gas within each micro-component to become excited to
emit radiation; and wherein optically inspecting comprises
optically inspecting each micro-component to determine if each
micro-component discharges the radiation and discarding comprises
discarding any micro-component that does not discharge the
radiation.
50. The process of claim 49, wherein applying the excitation field
comprises exciting each micro-component with an electron beam.
51. The process of claim 49, wherein applying the excitation field
comprises exciting each micro-component with a tesla coil.
52. The process of claim 49, wherein applying the excitation field
comprises exciting each micro-component with a high frequency RF
signal.
53. A method for conditioning a plurality of micro-components for
use in a plasma display, each micro-component emitting radiation
when exposed to an excitation field, the method comprising:
assembling the plurality of micro-components into a batch; applying
the excitation field to the batch of micro-components for a
predetermined amount of time; and terminating the excitation field
and individually testing operation of each one of the
micro-components.
54. The method of claim 53, wherein individually testing comprises
discarding micro-components which fail to operate.
55. The method of claim 53, wherein applying the excitation field
comprises applying the excitation field at a magnitude greater than
a second excitation field which is applied to the micro-components
when in the plasma display.
56. The method of claim 53, wherein applying the excitation field
comprises selecting the predetermined amount of time.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part of U.S. patent application
Ser. No. 09/697,358 entitled "A Micro-Component for Use in a
Light-Emitting Panel," filed Oct. 27, 2000, and claims priority to
that parent application's filing date. Also referenced hereby are
the following applications which are incorporated herein by
reference in their entireties, and the filing dates thereof to
which priority is also claimed: U.S. patent application Ser. No.
09/697,344 entitled "A Light-Emitting Panel and a Method for
Making," filed Oct. 27, 2000; U.S. patent application Ser. No.
09/697,498 entitled "A Method for Testing a Light-Emitting Panel
and the Components Therein," filed Oct. 27, 2000; U.S. patent
application Ser. No. 09/697,345 entitled "A Method and System for
Energizing a Micro-Component in a Light-Emitting Panel," filed Oct.
27, 2000; U.S. patent application Ser. No. 09/697,346 entitled "A
Socket for Use in a Light-Emitting Panel," filed Oct. 27, 2000;
U.S. patent application Ser. No. (Attorney Docket No.
SAIC0029-CIP2) entitled "Use of Printing and Other Technology for
Micro-Component Placement," filed concurrently herewith; U.S.
patent application Ser. No. (Attorney Docket No. SAIC0029-CIP1)
entitled "Liquid Manufacturing Processes for Panel Layer
Fabrication," filed concurrently herewith; U.S. patent application
Ser. No. (Attorney Docket No. SAIC0025-CIP) entitled "Method for
On-Line Testing of a Light-Emitting Panel," filed concurrently
herewith; and U.S. patent application Ser. No. (Attorney Docket No.
SAIC0026-CIP) entitled "Method and Apparatus for Addressing
Micro-Components in a Plasma Display Panel," filed concurrently
herewith.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a light-emitting panel and
methods of fabricating the same. The present invention further
relates to a micro-component for use in a light-emitting panel.
[0004] 2. Description of Related Art
[0005] In a typical plasma display, a gas or mixture of gases is
enclosed between orthogonally crossed and spaced conductors. The
crossed conductors define a matrix of cross over points, arranged
as an array of miniature picture elements (pixels), which provide
light. At any given pixel, the orthogonally crossed and spaced
conductors function as opposed plates of a capacitor, with the
enclosed gas serving as a dielectric. When a sufficiently large
voltage is applied, the gas at the pixel breaks down creating free
electrons that are drawn to the positive conductor and positively
charged gas ions that are drawn to the negatively charged
conductor. These free electrons and positively charged gas ions
collide with other gas atoms causing an avalanche effect creating
still more free electrons and positively charged ions, thereby
creating plasma. The voltage level at which this plasma-forming
discharge occurs is called the write voltage.
[0006] Upon application of a write voltage, the gas at the pixel
ionizes and emits light only briefly as free charges formed by the
ionization migrate to the insulating dielectric walls of the cell
where these charges produce an opposing voltage to the applied
voltage and thereby eventually extinguish the discharge. Once a
pixel has been written, a continuous sequence of light emissions
can be produced by an alternating sustain voltage. The amplitude of
the sustain waveform can be less than the amplitude of the write
voltage, because the wall charges that remain from the preceding
write or sustain operation produce a voltage that adds to the
voltage of the succeeding sustain waveform applied in the reverse
polarity to produce the ionizing voltage. Mathematically, the idea
can be set out as V.sub.s=V.sub.w-V.sub.wall, where V.sub.s is the
sustain voltage, V.sub.w is the write voltage, and V.sub.wall is
the wall voltage. Accordingly, a previously unwritten (or erased)
pixel cannot be ionized by the sustain waveform alone. An erase
operation can be thought of as a write operation that proceeds only
far enough to allow the previously charged cell walls to discharge;
it is similar to the write operation except for timing and
amplitude.
[0007] Typically, there are two different arrangements of
conductors that are used to perform the write, erase, and sustain
operations. The one common element throughout the arrangements is
that the sustain and the address electrodes are spaced apart with
the plasma-forming gas in between. Thus, at least one of the
address or sustain electrodes may be located partially within the
path the radiation travels, when the plasma-forming gas ionizes, as
it exits the plasma display. Consequently, transparent or
semi-transparent conductive materials must be used, such as indium
tin oxide (ITO), so that the electrodes do not interfere with the
displayed image from the plasma display. Using ITO, however, has
several disadvantages, for example, ITO is expensive and adds
significant cost to the manufacturing process and ultimately the
final plasma display.
[0008] The first arrangement uses two orthogonally crossed
conductors, one addressing conductor and one sustaining conductor.
In a gas panel of this type, the sustain waveform is applied across
all the addressing conductors and sustain conductors so that the
gas panel maintains a previously written pattern of light emitting
pixels. For a conventional write operation, a suitable write
voltage pulse is added to the sustain voltage waveform so that the
combination of the write pulse and the sustain pulse produces
ionization. In order to write an individual pixel independently,
each of the addressing and sustain conductors has an individual
selection circuit. Thus, applying a sustain waveform across all the
addressing and sustain conductors, but applying a write pulse
across only one addressing and one sustain conductor will produce a
write operation in only the one pixel at the intersection of the
selected addressing and sustain conductors.
[0009] The second arrangement uses three conductors. In panels of
this type, called coplanar sustaining panels, each pixel is formed
at the intersection of three conductors, one addressing conductor
and two parallel sustaining conductors. In this arrangement, the
addressing conductor orthogonally crosses the two parallel
sustaining conductors. With this type of panel, the sustain
function is performed between the two parallel sustaining
conductors and the addressing is done by the generation of
discharges between the addressing conductor and one of the two
parallel sustaining conductors.
[0010] The sustaining conductors are of two types,
addressing-sustaining conductors and solely sustaining conductors.
The function of the addressing-sustaining conductors is twofold: to
achieve a sustaining discharge in cooperation with the solely
sustaining conductors; and to fulfill an addressing role.
Consequently, the addressing-sustaining conductors are individually
selectable so that an addressing waveform may be applied to any one
or more addressing-sustaining conductors. The solely sustaining
conductors, on the other hand, are typically connected in such a
way that a sustaining waveform can be simultaneously applied to all
of the solely sustaining conductors so that they can be carried to
the same potential in the same instant.
[0011] Numerous types of plasma panel display devices have been
constructed with a variety of methods for enclosing a
plasma-forming gas between sets of electrodes. In one type of
plasma display panel, parallel plates of glass with wire electrodes
on the surfaces thereof are spaced uniformly apart and sealed
together at the outer edges with the plasma-forming gas filling the
cavity formed between the parallel plates. Although widely used,
this type of open display structure has various disadvantages. The
sealing of the outer edges of the parallel plates, the pumping down
to vacuum, the baking out under vacuum, and the introduction of the
plasma-forming gas are both expensive and time-consuming processes,
resulting in a costly end product. In addition, it is particularly
difficult to achieve a good seal at the sites where the electrodes
are fed through the ends of the parallel plates. This can result in
gas leakage and a shortened product lifecycle. Another disadvantage
is that individual pixels are not segregated within the parallel
plates. As a result, gas ionization activity in a selected pixel
during a write operation may spill over to adjacent pixels, thereby
raising the undesirable prospect of possibly igniting adjacent
pixels without a write pulse being applied. Even if adjacent pixels
are not ignited, the ionization activity can change the turn-on and
turn-off characteristics of the nearby pixels.
[0012] In another type of known plasma display, individual pixels
are mechanically isolated either by forming trenches in one of the
parallel plates or by adding a perforated insulating layer
sandwiched between the parallel plates. These mechanically isolated
pixels, however, are not completely enclosed or isolated from one
another because there is a need for the free passage of the
plasma-forming gas between the pixels to assure uniform gas
pressure throughout the panel. While this type of display structure
decreases spill over, spill over is still possible because the
pixels are not in total physical isolation from one another. In
addition, in this type of display panel it is difficult to properly
align the electrodes and the gas chambers, which may cause pixels
to misfire. As with the open display structure, it is also
difficult to get a good seal at the plate edges. Furthermore, it is
expensive and time consuming to pump down to vacuum, bake out under
vacuum, introduce the plasma producing gas and seal the outer edges
of the parallel plates.
[0013] In yet another type of known plasma display, individual
pixels are also mechanically isolated between parallel plates. In
this type of display, the plasma-forming gas is contained in
transparent spheres formed of a closed transparent shell. Various
methods have been used to contain the gas filled spheres between
the parallel plates. In one method, spheres of varying sizes are
tightly bunched and randomly distributed throughout a single layer,
and sandwiched between the parallel plates. In a second method,
spheres are embedded in a sheet of transparent dielectric material
and that material is then sandwiched between the parallel plates.
In a third method, a perforated sheet of electrically nonconductive
material is sandwiched between the parallel plates with the gas
filled spheres distributed in the perforations.
[0014] While each of the types of displays discussed above are
based on different design concepts, the manufacturing approach used
in their fabrication is generally the same. Conventionally, a batch
fabrication process is used to manufacture these types of plasma
panels. As is well known in the art, in a batch process individual
component parts are fabricated separately, often in different
facilities and by different manufacturers, and then brought
together for final assembly where individual plasma panels are
created one at a time. Batch processing has numerous shortcomings,
such as, for example, the length of time necessary to produce a
finished product. Long cycle times increase product cost and are
undesirable for numerous additional reasons known in the art. For
example, a sizeable quantity of substandard, defective, or useless
fully or partially completed plasma panels may be produced during
the period between detection of a defect or failure in one of the
components and an effective correction of the defect or
failure.
[0015] This is especially true of the first two types of displays
discussed above; the first having no mechanical isolation of
individual pixels, and the second with individual pixels
mechanically isolated either by trenches formed in one parallel
plate or by a perforated insulating layer sandwiched between two
parallel plates. Due to the fact that plasma-forming gas is not
isolated at the individual pixel/subpixel level, the fabrication
process precludes the majority of individual component parts from
being tested until the final display is assembled. Consequently,
the display can only be tested after the two parallel plates are
sealed together and the plasma-forming gas is filled inside the
cavity between the two plates. If post production testing shows
that any number of potential problems have occurred, (e.g. poor
luminescence or no luminescence at specific pixels/subpixels) the
entire display is discarded.
BRIEF SUMMARY OF THE INVENTION
[0016] Preferred embodiments of the present invention provide a
light-emitting panel that may be used as a large-area radiation
source, for energy modulation, for particle detection and as a
flat-panel display. Gas-plasma panels are preferred for these
applications due to their unique characteristics.
[0017] In one basic form, the light-emitting panel may be used as a
large area radiation source. By configuring the light-emitting
panel to emit ultraviolet (UV) light, the panel has application for
curing paint or other coatings, and for sterilization. With the
addition of one or more phosphor coatings to convert the UV light
to visible white light, the panel also has application as an
illumination source.
[0018] In addition, the light-emitting panel may be used as a
plasma-switched phase array by configuring the panel in at least
one embodiment in a microwave transmission mode. The panel is
configured in such a way that during ionization the plasma-forming
gas creates a localized index of refraction change for the
microwaves (although other electromagnetic wavelengths would work).
The microwave beam from the panel can then be steered or directed
in any desirable pattern by introducing at a localized area a phase
shift and/or directing the microwaves out of a specific aperture in
the panel
[0019] Additionally, the light-emitting panel may be used for
particle/photon detection. In this embodiment, the light-emitting
panel is subjected to a potential that is just slightly below the
write voltage required for ionization. When the device is subjected
to outside energy at a specific position or location in the panel,
that additional energy causes the plasma-forming gas in the
specific area to ionize, thereby providing a means of detecting
outside energy.
[0020] Further, the light-emitting panel may be used in flat-panel
displays. These displays can be manufactured very thin and
lightweight, when compared to similar sized cathode ray tube
(CRTs), making them ideally suited for home, office, theaters and
billboards. In addition, these displays can be manufactured in
large sizes and with sufficient resolution to accommodate
high-definition television (HDTV). Gas-plasma panels do not suffer
from electromagnetic distortions and are, therefore, suitable for
applications strongly affected by magnetic fields, such as military
applications, radar systems, railway stations and other underground
systems.
[0021] According to a general embodiment of the present invention,
a light-emitting panel is made from two substrates, wherein one of
the substrates includes a plurality of sockets and wherein at least
two electrodes are disposed. At least partially disposed in each
socket is a micro-component, although more than one micro-component
may be disposed therein. Each micro-component includes a shell at
least partially filled with a gas or gas mixture capable of
ionization. When a large enough voltage is applied across the
micro-component the gas or gas mixture ionizes forming plasma and
emitting radiation.
[0022] In one embodiment of the present invention, the
micro-component is configured to emit ultra-violet (UV) light,
which may be converted to visible light by at least partially
coating each micro-component with phosphor. To obtain an
improvement in the discharge characteristics, each micro-component
may be at least partially coated with a secondary emission
enhancement material.
[0023] In another embodiment, each micro-component is at least
partially coated with a reflective material. An index matching
material is disposed so as to be in contact with at least a portion
of the reflective material. The combination of the index matching
material and the reflective material permits a predetermined
wavelength of light to be emitted from each micro-component at the
point of contact between the index matching material and the
reflective material.
[0024] Another object of the present invention is to provide a
micro-component for use in a light-emitting panel. A shell at least
partially filled with at least one plasma-forming gas provides the
basic micro-component structure. The shell may be doped or ion
implanted with a conductive material, a material that provides
secondary emission enhancement, and/or a material that converts UV
light to visible light. The micro-components will be made as a
sphere, cylinder or any other shape. The size and shape will be
determined in accordance with the desired resolution for the
display panel to be assembled. Typical sizes are about hundreds of
microns independent of shape.
[0025] Another preferred embodiment of the present invention is to
provide a method of making a micro-component. In one embodiment,
the method is part of a continuous process, where a shell is at
least partially formed in the presence of at least one
plasma-forming gas, such that when formed, the shell is filled with
the plasma-forming gas or gas mixture.
[0026] In another embodiment, the micro-component is made by
affixing a first substrate to a second substrate in the presence of
at least one plasma-forming gas. In this method, either the first
and/or the second substrate contains a plurality of cavities so
that when the first substrate is affixed to the second substrate
the plurality of cavities are filled with the plasma-forming gas or
gas mixture. In a preferred embodiment, a first substrate is
advanced through a first roller assembly, which includes a roller
with a plurality of nodules and a roller with a plurality of
depressions. Both the plurality of nodules and the plurality of
depressions are in registration with each other so that when the
first substrate passes through the first roller assembly, the first
substrate has a plurality of cavities formed therein. A second
substrate is advanced through a second roller assembly and then
affixed to the first substrate in the presence of at least one gas
so that when the two substrates are affixed the cavities are filled
with the gas or gas mixture. In an alternate preferred embodiment,
the second roller assembly includes a roller with a plurality of
nodules and a roller with a plurality of depressions so that when
the second substrate passes through the second roller assembly, the
second substrate also has a plurality of cavities formed therein.
In either of these embodiments, at least one electrode may be
sandwiched between the first and second substrates prior to the
substrates being affixed.
[0027] In another embodiment, at least one substrate is thermally
treated in the presence of a least one plasma-forming gas so as to
form shells filled with the plasma-forming gas or gas-mixture.
[0028] In a specific aspect, the micro-components, whether sphere,
capillary or other shape are coated with a frequency converting
coating. Phosphor is an example of such a coating. More
specifically, the coating converts electromagnetic radiation
generated in the plasma in the ultraviolet region of the spectrum,
and converts it to the visible red, blue or green region of the
spectrum.
[0029] Alternatives include putting a drop of the frequency
converting material in a socket into which the micro-component is
placed, or the micro-component itself can be doped with a material
such as a rare earth that is a frequency converter. Examples of
materials include barium fluoride or the like, yttrium aluminum
garnet, or gadolinium gallium garnet. The plasma gases in the
micro-component can include xenon chloride, argon chloride, etc.,
namely the rare gas halides.
[0030] In another aspect, the micro-components are tested as they
are manufactured. The micro-components are optionally scanned for
certain physical characteristics or defects, for example, in an
optical field detecting shape such as sphericity and size as they
drop through a tower. A micro-component displacement device can be
used to remove those that are bad. At a subsequent layer, as they
drop the micro-components are subjected to electron beam
excitation, microwave or RF field, for example, to excite the gas.
Another physical characteristic or defect is tested, such as if a
certain luminous output is achieved, and if achieved, it is
preliminarily accepted. Those for which a desired luminous output
is not achieved are discarded, for example, through the use of a
second micro-component displacement device.
[0031] In yet still another aspect, the micro-components are
preconditioned by being excited for a predetermined period of time.
Examples include taking the micro-components that passed the
initial test, placing them in a container and exciting them, for
example, for 5 to 10 hours. Alternatively, they can be placed
between large parallel electrodes. After the batch run, they are
dropped through a tower as they are excited, output detected and
the ones that do not excite are knocked out of the stream.
[0032] Other features, advantages, and embodiments of the invention
are set forth in part in the description that follows, and in part,
will be obvious from this description, or may be learned from the
practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The foregoing and other features and advantages of this
invention will become more apparent by reference to the following
detailed description of the invention taken in conjunction with the
accompanying drawings.
[0034] FIG. 1 shows a socket with a micro-component disposed
therein.
[0035] FIG. 2 depicts a portion of a light-emitting panel showing a
plurality of micro-components disposed in sockets.
[0036] FIG. 3A shows an example of a cavity that has a cube
shape.
[0037] FIG. 3B shows an example of a cavity that has a cone
shape.
[0038] FIG. 3C shows an example of a cavity that has a conical
frustum shape.
[0039] FIG. 3D shows an example of a cavity that has a paraboloid
shape.
[0040] FIG. 3E shows an example of a cavity that has a spherical
shape.
[0041] FIG. 3F shows an example of a cavity that has a
hemi-cylindrical shape.
[0042] FIG. 3G shows an example of a cavity that has a pyramid
shape.
[0043] FIG. 3H shows an example of a cavity that has a pyramidal
frustum shape.
[0044] FIG. 3I shows an example of a cavity that has a
parallelepiped shape.
[0045] FIG. 3J shows an example of a cavity that has a prism
shape.
[0046] FIG. 4 shows an apparatus used in an embodiment of the
present invention as part of a continuous process for forming
micro-components.
[0047] FIG. 5 shows an apparatus used in an embodiment of the
present invention as part of another process for forming
micro-components.
[0048] FIG. 6 shows an variation of the apparatus shown in FIG. 5,
which is used as part of another process for forming
micro-components.
[0049] FIG. 7 illustrates an example of selection of pixel size and
micro-component (micro-sphere) size for different sized high
definition television (HDTV) displays, which can be manufactured
according to the micro-component method hereof.
[0050] FIG. 8 is a table showing numbers of pixels for various
standard display resolutions.
[0051] FIG. 9 illustrates, according to an embodiment, one way in
which an electrode may be disposed between two substrates as part
of a process for forming micro-components.
[0052] FIG. 10 depicts the steps of another method for forming
micro-components.
[0053] FIG. 11 shows an apparatus used in an embodiment of the
present invention as part of a continuous process for forming
micro-components similar to that of FIG. 4, and including a
mechanism for pretesting or pre-screening of micro-components prior
to assembly in a panel.
[0054] FIG. 12 shows an apparatus used for batch conditioning of
micro-components.
[0055] FIG. 13 shows an alternative embodiment of an apparatus used
for batch conditioning of micro-components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE
INVENTION
[0056] As embodied and broadly described herein, the preferred
embodiments of the present invention are directed to a novel
light-emitting panel. In particular, the preferred embodiments are
directed to a micro-component capable of being used in the
light-emitting panel and at least partially disposed in at least
one socket.
[0057] FIGS. 1 and 2 show two embodiments of the present invention
wherein a light-emitting panel includes a first substrate 10 and a
second substrate 20. The first substrate 10 may be made from
silicates, polypropylene, quartz, glass, any polymeric-based
material or any material or combination of materials known to one
skilled in the art. Similarly, second substrate 20 may be made from
silicates, polypropylene, quartz, glass, any polymeric-based
material or any material or combination of materials known to one
skilled in the art. First substrate 10 and second substrate 20 may
both be made from the same material or each of a different
material. Additionally, the first and second substrate may be made
of a material that dissipates heat from the light-emitting panel.
In a preferred embodiment, each substrate is made from a material
that is mechanically flexible.
[0058] The first substrate 10 includes a plurality of sockets 30. A
cavity 55 formed within and/or on the first substrate 10 provides
the basic socket 30 structure. The cavity 55 may be any shape and
size. As depicted in FIGS. 3A-3J, the shape of the cavity 55 may
include, but is not limited to, a cube 100, a cone 110, a conical
frustum 120, a paraboloid 130, spherical 140, cylindrical 150, a
pyramid 160, a pyramidal frustum 170, a parallelepiped 180, or a
prism 190. The size and shape of the socket 30 influence the
performance and characteristics of the light-emitting panel and are
selected to optimize the panel's efficiency of operation. In
addition, socket geometry may be selected based on the shape and
size of the micro-component to optimize the surface contact between
the micro-component and the socket and/or to ensure connectivity of
the micro-component and any electrodes disposed within the socket.
Further, the size and shape of the sockets 30 may be chosen to
optimize photon generation and provide increased luminosity and
radiation transport efficiency.
[0059] At least partially disposed in each socket 30 is at least
one micro-component 40. Multiple micro-components may be disposed
in a socket to provide increased luminosity and enhanced radiation
transport efficiency. In a color light-emitting panel according to
one embodiment of the present invention, a single socket supports
three micro-components configured to emit red, green, and blue
light, respectively. The micro-components 40 may be of any shape,
including, but not limited to, spherical, cylindrical, and
aspherical. In addition, it is contemplated that a micro-component
40 includes a micro-component placed or formed inside another
structure, such as placing a spherical micro-component inside a
cylindrical-shaped structure. In a color light-emitting panel
according to an embodiment of the present invention, each
cylindrical-shaped structure holds micro-components configured to
emit a single color of visible light or multiple colors arranged
red, green, blue, or in some other suitable color arrangement.
[0060] In another embodiment of the present invention, an adhesive
or bonding agent is applied to each micro-component to assist in
placing/holding a micro-component 40 or plurality of
micro-components in a socket 30. In an alternative embodiment, an
electrostatic charge is placed on each micro-component and an
electrostatic field is applied to each micro-component to assist in
the placement of a micro-component 40 or plurality of
micro-components in a socket 30. Applying an electrostatic charge
to the micro-components also helps avoid agglomeration among the
plurality of micro-components. In one embodiment of the present
invention, an electron gun is used to place an electrostatic charge
on each micro-component and one electrode disposed proximate to
each socket 30 is energized to provide the needed electrostatic
field required to attract the electrostatically charged
micro-component.
[0061] In its most basic form, each micro-component 40 includes a
shell 50 filled with a plasma-forming gas or gas mixture 45. Any
suitable gas or gas mixture 45 capable of ionization may be used as
the plasma-forming gas, including, but not limited to, krypton,
xenon, argon, neon, oxygen, helium, mercury, and mixtures thereof.
In fact, any noble gas could be used as the plasma-forming gas,
including, but not limited to, noble gases mixed with cesium or
mercury. Further, rare gas halide mixtures such as xenon chloride,
xenon fluoride and the like are also suitable plasma-forming gases.
Rare gas halides are efficient radiators having radiating
wavelengths of approximately 300 to 350 nm, which is longer than
that of pure xenon (147 to 170 nm). This results in an overall
quantum efficiency gain, ie., a factor of two or more, given by the
mixture ratio. Still further, in another embodiment of the present
invention, rare gas halide mixtures are also combined with other
plasma-forming gases as listed above. This description is not
intended to be limiting. One skilled in the art would recognize
other gasses or gas mixtures that could also be used. In a color
display, according to another embodiment, the plasma-forming gas or
gas mixture 45 is chosen so that during ionization the gas will
irradiate a specific wavelength of light corresponding to a desired
color. For example, neon-argon emits red light, xenon-oxygen emits
green light, and krypton-neon emits blue light. While a
plasma-forming gas or gas mixture 45 is used in a preferred
embodiment, any other material capable of providing luminescence is
also contemplated, such as an electro-luminescent material, organic
light-emitting diodes (OLEDs), or an electro-phoretic material.
[0062] The shell 50 may be made from a wide assortment of
materials, including, but not limited to, silicates, polypropylene,
glass, any polymeric-based material, magnesium oxide and quartz and
may be of any suitable size. The shell 50 may have a diameter
ranging from micrometers to centimeters as measured across its
minor axis, with virtually no limitation as to its size as measured
across its major axis. For example, a cylindrical-shaped
micro-component may be only 100 microns in diameter across its
minor axis, but may be hundreds of meters long across its major
axis. In a preferred embodiment, the outside diameter of the shell,
as measured across its minor axis, is from 100 microns to 300
microns. In addition, the shell thickness may range from
micrometers to millimeters, with a preferred thickness from 1
micron to 10 microns.
[0063] When a sufficiently large voltage is applied across the
micro-component the gas or gas mixture ionizes forming plasma and
emitting radiation. In FIG. 2, a two electrode configuration is
shown including a first sustain electrode 520 and an address
electrode 530. In FIG. 1, a three electrode configuration is shown,
wherein a first sustain electrode 520, an address electrode 530 and
a second sustain electrode 540 are disposed within a plurality of
material layers 60 that form the first substrate 10. The potential
required to initially ionize the gas or gas mixture inside the
shell 50 is governed by Paschen's Law and is closely related to the
pressure of the gas inside the shell. In the present invention, the
gas pressure inside the shell 50 ranges from tens of torrs to
several atmospheres. In a preferred embodiment, the gas pressure
ranges from 100 torr to 700 torr or higher pressure as appropriate.
The size and shape of a micro-component 40 and the type and
pressure of the plasma-forming gas contained therein, influence the
performance and characteristics of the light-emitting panel and are
selected to optimize the panel's efficiency of operation.
[0064] There are a variety of coatings 300 and dopants that may be
added to a micro-component 40 that also influence the performance
and characteristics of the light-emitting panel. The coatings 300
may be applied to the outside or inside of the shell 50, and may
either partially or fully coat the shell 50. Types of outside
coatings include, but are not limited to, coatings used to convert
UV light to visible light (e.g. phosphor), coatings used as
reflecting filters, and coatings used as bandpass filters. Types of
inside coatings include, but are not limited to, coatings used to
convert UV light to visible light (e.g. phosphor), coatings used to
enhance secondary emissions and coatings used to prevent erosion.
One skilled in the art will recognize that other coatings may also
be used. The coatings 300 may be applied to the shell 50 by
differential stripping, lithographic process, sputtering, laser
deposition, chemical deposition, vapor deposition, or deposition
using ink jet technology. One skilled in the art will realize that
other methods of coating the inside and/or outside of the shell 50
may also work. Types of dopants include, but are not limited to,
dopants used to convert UV light to visible light (e.g. phosphor),
dopants used to enhance secondary emissions and dopants used to
provide a conductive path through the shell 50. The dopants are
added to the shell 50 by any suitable technique known to one
skilled in the art, including ion implantation. It is contemplated
that any combination of coatings and dopants may be added to a
micro-component 40.
[0065] In an embodiment of the present invention, when a
micro-component is configured to emit UV light, the UV light is
converted to visible light by at least partially coating the inside
of the shell 50 with phosphor, at least partially coating the
outside of the shell 50 with phosphor, doping the shell 50 with
phosphor and/or coating the inside of a socket 30 with phosphor. In
a color panel, according to an embodiment of the present invention,
colored phosphor is chosen so the visible light emitted from
alternating micro-components is colored red, green and blue,
respectively. By combining these primary colors at varying
intensities, all colors can be formed. It is contemplated that
other color combinations and arrangements may be used.
[0066] To obtain an improvement in discharge characteristics, in an
embodiment of the present invention, the shell 50 of each
micro-component 40 is at least partially coated on the inside
surface with a secondary emission enhancement material. Any low
affinity material may be used including, but not limited to,
magnesium oxide and thulium oxide. One skilled in the art would
recognize that other materials will also provide secondary emission
enhancement. In another embodiment of the present invention, the
shell 50 is doped with a secondary emission enhancement material.
It is contemplated that the doping of shell 50 with a secondary
emission enhancement material may be in addition to coating the
shell 50 with a secondary emission enhancement material. In this
case, the secondary emission enhancement material used to coat the
shell 50 and dope the shell 50 may be different.
[0067] Alternatively to the previously discussed phosphor which can
be used to coat the micro-component, or alternatively, placed into
a socket in a display panel in which the micro-components are
placed, the micro-component material can be doped with a rare earth
that is a frequency converter. Such dopants can include barium
fluoride or similar materials such as yttrium aluminum garnet, or
gadolinium gallium garnet. These types of frequency converting
materials serve to convert plasma light at the UV wavelength to
visible light of red, blue or green color. The gasses in the
micro-component in such cases will include rare gas halide mixtures
such as xenon chloride, xenon fluoride and the like. Rare gas
halides are efficient radiators having radiating wavelengths of
approximately 300 to 350 nm, which is longer than that of pure
xenon (147 to 170 nm). This results in an overall quantum
efficiency gain, i.e., a factor of two or more, given by the
mixture ratio. Still further, in another embodiment of the present
invention, rare gas halide mixtures are also combined with other
plasma-forming gases as listed previously. This description is not
intended to be limiting. In the case when such frequency converting
materials are used, instead of using a phosphor coating, they can
be integrated as a dopant in the shell of the micro-component. For
example, yttrium aluminum garnet doped with cerium can serve to
convert UV wavelengths from rare gas halides into green light.
[0068] In addition to, or in place of, doping the shell 50 with a
secondary emission enhancement material, according to an embodiment
of the present invention, the shell 50 is doped with a conductive
material. Possible conductive materials include, but are not
limited to silver, gold, platinum, and aluminum. Doping the shell
50 with a conductive material, either in two or more localized
areas to provide separate electrode-like paths or in a way to
produce anisotropic conductivity in the shell (high perpendicular
conductivity, low in-plane conductivity), provides a direct
conductive path to the gas or gas mixture contained in the shell
and provides one possible means of achieving a DC light-emitting
panel. In this manner, shorting is avoided and two or more separate
electrode paths are maintained to allow exciting of the gas.
[0069] In another embodiment of the present invention, the shell 50
of the micro-component 40 is coated with a reflective material. An
index matching material that matches the index of refraction of the
reflective material is disposed so as to be in contact with at
least a portion of the reflective material. The reflective coating
and index matching material may be separate from, or in conjunction
with, the phosphor coating and secondary emission enhancement
coating of previous embodiments. The reflective coating is applied
to the shell 50 in order to enhance radiation transport. By also
disposing an index-matching material so as to be in contact with at
least a portion of the reflective coating, a predetermined
wavelength range of radiation is allowed to escape through the
reflective coating at the interface between the reflective coating
and the index-matching material. By forcing the radiation out of a
micro-component through the interface area between the reflective
coating and the index-matching material greater micro-component
efficiency is achieved with an increase in luminosity. In an
embodiment, the index matching material is coated directly over at
least a portion of the reflective coating. In another embodiment,
the index matching material is disposed on a material layer, or the
like, that is brought in contact with the micro-component such that
the index matching material is in contact with at least a portion
of the reflective coating. In another embodiment, the size of the
interface is selected to achieve a specific field of view for the
light-emitting panel.
[0070] Several methods are proposed, in various embodiments, for
making a micro-component for use in a light-emitting panel. It has
been contemplated that each of the coatings and dopants that may be
added to a micro-component 40, as disclosed herein, may also be
included in steps in forming a micro-component, as discussed
herein.
[0071] In one embodiment of the present invention, a continuous
inline process for making a micro-component is described, where a
shell is at least partially formed in the presence of at least one
plasma-forming gas, such that when formed, the shell is filled with
the gas or gas mixture. In a preferred embodiment, the process
takes place in a drop tower. According to FIG. 4, and as an example
of one of many possible ways to make a micro-component as part of a
continuous inline process, a droplet generator 600 including a
pressure transducer port 605, a liquid inlet port 610, a
piezoelectric transducer 615, a transducer drive signal electrode
620, and an orifice plate 625, produces uniform water droplets of a
predetermined size. The droplets pass through an encapsulation
region 630 where each water droplet is encased in a gel outer
membrane formed of an aqueous solution of glass forming oxides (or
any other suitable material that may be used for a micro-component
shell), which is then passed through a dehydration region 640
leaving a hollow dry gel shell. This dry gel shell then travels
through a transition region 650 where it is heated into a glass
shell (or other type of shell depending on what aqueous solution
was chosen) and then finally through a refining region 660. While
it is possible to introduce a plasma-forming gas or gas mixture
into the process during any one of the steps, it is preferred in an
embodiment of the present invention to perform the whole process in
the presence of the plasma-forming gas or gas mixture. Thus, when
the shell leaves the refining region 660, the plasma-forming gas or
gas mixture is sealed inside the shell thereby forming a
micro-component.
[0072] In an embodiment of the present invention, the above process
is modified so that the shell can be doped with either a secondary
emission enhancement material and/or a conductive material,
although other dopants may also be used. While it is contemplated
that the dopants may be added to the shell by ion implantation at
later stages in the process, in a preferred embodiment, the dopant
is added directly in the aqueous solution so that the shell is
initial formed with the dopant already present in the shell.
[0073] The above process steps may be modified or additional
process steps may be added to the above process for forming a
micro-component to provide a means for adding at least one coating
to the micro-component. For coatings that may be disposed on the
inside of the shell including, but not limited to a secondary
emission enhancement material and a conductive material, it is
contemplated in an embodiment of the present invention that those
coating materials are added to the initial droplet solution so that
when the outer membrane is formed around the initial droplet and
then passed through the dehydration region 640 the coating material
is left on the inside of the hollow dry gel shell. For coatings
that may be disposed on the outside of the shell including, but not
limited to, coatings used to convert UV light to visible light,
coatings used as reflective filters and coatings used as band-gap
filters, it is contemplated that after the micro-component leaves
the refining region 660, the micro-component component will travel
through at least one coating region. The coatings may be applied by
any number of processes known to those skilled in the art as a
means of applying a coating to a surface.
[0074] A further modification of the drop tower of FIG. 4 is
illustrated in FIG. 11 with a continuous testing region 801. The
continuous testing region 801 includes a first optical detector 821
which detects individual micro-components as they are formed. This
optical detector can detect such things as sphericity and size in a
continuous process, typically operating at about 10 kilohertz
sampling rate. Signals representing the micro-component detected
are passed through line 823 to a control module 825. If a
micro-component does not meet certain minimum standards, a signal
is sent from control module 825 to mechanical actuator 827 which
activates a micro-component displacement device or arm 829 which is
activated to remove the failed micro-component from the stream. A
second region of the continuing testing device 801 includes,
optionally, electrodes 805 which are excited through leads 807 by
power supply 809 to generate a field which excites the plasma gas
within the manufactured micro-components. As the micro-components
are exited, a luminous output is generated and a second optical
detector 811 serves to detect the luminous output and send a signal
representing the luminous output for each individual
micro-component through line 813 to a second control unit 815.
[0075] If no luminous output is detected or a luminous output of
less than a predetermined threshold is detected, the control unit
815 sends a signal to actuator 817 which then actuates a second
micro-component displacement device or arm 819 to remove the failed
micro-component from the stream.
[0076] With respect to the photo-detectors, they are conventional,
and can be of the type, for example, which detect UV light.
Alternatively, if the micro-component has been coated prior to the
end of the fabrication process, for example, with phosphor, the
detector may be of the type which is sensitive to a red light
output. It should be noted that although the micro-component
displacement devices or arms 819 and 829 have been described as
mechanical in nature, they may also be non-mechanical, such as an
intermittent fluid stream such as a gas or liquid stream or a light
pulse such as a high-intensity laser pulse.
[0077] In another embodiment of the present invention, two
substrates are provided, wherein at least one of two substrates
contain a plurality of cavities. The two substrates are affixed
together in the presence of at least one plasma-forming gas so that
when affixed, the cavities are filled with the gas or gas mixture.
In an embodiment of the present invention at least one electrode is
disposed between the two substrates. In another embodiment, the
inside, the outside, or both the inside and the outside of the
cavities are coated with at least one coating. It is contemplated
that any coating that may be applied to a micro-component as
disclosed herein may be used. As illustrated in FIG. 5, one method
of making a micro-component in accordance with this embodiment of
the present invention is to take a first substrate 200 and a second
substrate 210 and then pass the first substrate 200 and the second
substrate 210 through a first roller assembly and a second roller
assembly, respectively. The first roller assembly includes a first
roller with nodules 224 and a first roller with depressions 228.
The first roller with nodules 224 is in register with the first
roller with depressions 228 so that as the first substrate 200
passes between the first roller with nodules 224 and the first
roller with depressions 228, a plurality of cavities 240 are formed
in the first substrate 200. As may be appreciated, the cavities may
be in the shape desired for micro-components manufactured therewith
such as hemispheres, capillaries, cylinders, etc. The second roller
assembly, according to a preferred embodiment, includes two second
rollers, 232 and 234. The first substrate 200, with a plurality of
cavities 240 formed therein, is brought together with the second
substrate 210 in the presence of a plasma-forming gas or gas
mixture and then affixed, thereby forming a plurality of
micro-components 250 integrally formed into a sheet of
micro-components. While the first substrate 200 and the second
substrate 210 may be affixed by any suitable method, according to a
preferred embodiment, the two substrates are thermally affixed by
heating the first roller with depressions 228 and the second roller
234.
[0078] The nodules on the first roller with nodules 224 may be
disposed in any pattern, having even or non-even spacing between
adjacent nodules. Patterns may include, but are not limited to,
alphanumeric characters, symbols, icons, or pictures. Preferably,
the distance between adjacent nodules is approximately equal. The
nodules may also be disposed in groups such that the distance
between one group of nodules and another group of nodules is
approximately equal. This latter approach may be particularly
relevant in color light-emitting panels, where each nodule in a
group of nodules may be used to form a micro-component that is
configured for red, green, and blue, respectively.
[0079] While it is preferred that the second roller assembly simply
include two second rollers, 232 and 234, in an embodiment of the
present invention as illustrated in FIG. 6, the second roller
assembly may also include a second roller with nodules 236 and a
second roller with depressions 238 that are in registration so that
when the second substrate 210 passes between the second roller with
nodules 236 and the second roller with depressions 238, a plurality
of cavities 260 are also formed in the second substrate 210. The
first substrate 200 and the second substrate 210 are then brought
together in the presence of at least one gas so that the plurality
of cavities 240 in the first substrate 200 and the plurality of
cavities 260 in the second substrate 210 are in register. The two
substrates are then affixed, thereby forming a plurality of
micro-components 270 integrally formed into a sheet of
micro-components. While the first substrate 200 and the second
substrate 240 may be affixed by any suitable method, according to a
preferred embodiment, the two substrates are thermally affixed by
heating the first roller with depressions 228 and the second roller
with depressions 238.
[0080] In an embodiment of the present invention that is applicable
to the two methods discussed above, and illustrated in FIG. 9, at
least one electrode 280 is disposed on or within the first
substrate 200, the second substrate 240 or both the first substrate
and the second substrate. Depending on how the electrode or
electrodes are disposed, the electrode or electrodes will provide
the proper structure for either an AC or DC (FIG. 7) light-emitting
panel. That is to say, if the at least one electrode 280 is at
least partially disposed in a cavity 240 or 260 then there will be
a direct conductive path between the at least one electrode and the
plasma-forming gas or gas mixture and the panel will be configured
for D.C. If, on the other hand, the at least one electrode is
disposed so as not to be in direct contact with the plasma-forming
gas or gas mixture, the panel will be configured for A.C.
[0081] In another embodiment of the present invention, at least one
substrate is thermally treated in the presence of at least one
plasma-forming gas, to form a plurality of shells 50 filled with
the plasma-forming gas or gas mixture. In a preferred embodiment of
the present invention, as shown in FIG. 10, the process for making
a micro-component would entail starting with a material or material
mixture 700, introducing inclusions into the material 710,
thermally treating the material so that the inclusions start
forming bubbles within the material 720 and those bubbles coalesce
730 forming a porous shell 740, and cooling the shell. The process
is performed in the presence of a plasma-forming gas so that when
the shell cools the plasma-forming gas 45 is sealed inside the
shell 50. This process can also be used to create a micro-component
with a shell doped with a conductive material and/or a secondary
emission enhancement material by combining the appropriate dopant
with the initial starting material or by introducing the
appropriate dopant while the shell is still porous.
[0082] In a yet still further method of manufacture, the
micro-components can be manufactured using any of the
above-mentioned methods, but not in the presence of a
plasma-forming gas, and either in a vacuum, air or other atmosphere
such as an inert atmosphere. They can be fabricated with one or two
openings, and the initial gas inside can be drawn out, for example,
through injection of plasma-forming gas through one opening,
forcing the gas therein out the other opening. The openings can
then be sealed conventionally.
[0083] In yet another alternative method, a device having one or
more micro-pippettes can create the micro-components much like
conventional glass blowing. The gas used to effect the
glass-blowing operation can be one of the aforementioned
plasma-forming gasses.
[0084] In yet still another alternative, an optical fiber extrusion
device can be used to manufacture the micro-components. Like an
optical fiber, which is solid, the device can be used to extrude a
capillary which is hollow on the inside. The capillary can then be
cut, filled with plasma-forming gas and sealed.
[0085] With respect to the selection of materials and dimensions
for the micro-components manufactured in the manner described
herein, they are manufactured to meet requirements for various
standard display resolutions. FIG. 7 illustrates an example of
calculation of pixel size and micro-component size, in the case
where the micro-components are spheres, for 42-inch and 60-inch
high definition television display having a 16:9 aspect ratio. FIG.
8 is a table showing numbers of pixels for various standard display
resolutions, and using the process for manufacturing in accordance
with the invention herein, such standards can be easily met.
[0086] In a further aspect, once the micro-components are
manufactured, it is desirable to condition them prior to assembly
into a plasma display panel. By conditioning is meant exciting them
for a time and at an excitation sufficient to cause those
micro-components which are likely to fail a short time after
assembly in a plasma display panel, to fail prior to assembly. In
this manner the yield relative to non-defective micro-components
which are eventually assembled into a plasma display panel is
significantly increased. Examples of devices for achieving said
conditioning are shown in FIGS. 11 and 12. As shown in the
conditioning device 951 of FIG. 11 the manufactured and pretested
micro-components 959 can be assembled between two conducting metal
plates 957 which are powered through leads 955 by a voltage source
953 which can take various forms as illustrated therein. The
micro-components 959 are subjected to a field sufficient to excite
the plasma gas contained therein, and preferably at a level higher
than any excitation level achieved when assembled in a plasma
display panel. This is done for a period of time sufficient such
that any micro-components which are prone to fail, will fail during
the conditioning phase, typically five to ten hours.
[0087] As may be appreciated, an alternative system is illustrated
by FIG. 13 which shows a conditioning device 901 which further
includes a container 909 for confining and containing
micro-components 911. The container 909 may be placed between
parallel plates or electrodes 903 which are powered through leads
905 by a power source 907 such as a voltage source of the type
previously discussed with reference to FIG. 11. The advantage of
such a system is that by having container 909, the micro-components
are easily contained. After the conditioning period, the individual
micro-components can then be dropped through a system such as
pretesting device 801 shown in FIG. 11 without the presence of
manufacturing drop tower 600, and tested previously described for
the method during which the micro-components are assembled. In this
manner, those micro-components which failed the conditioning are
eliminated and only fully-functioning micro-components can then be
assembled into a plasma display panel as heretofore described.
[0088] With respect to micro-components manufactured as discussed
with reference to FIGS. 5, 6, and 9, once assembled, they may be
cut from the sheets on which they are formed. They can be pretested
with a device such as shown in the lower half of FIG. 11 at 801 and
803. They can then be pre-conditioned as previously described with
reference to FIGS. 12 and 13, and then retested with the device of
the lower half of FIG. 11 at 801 and 803.
[0089] Other embodiments and uses of the present invention will be
apparent to those skilled in the art from consideration of this
application and practice of the invention disclosed herein. The
present description and examples should be considered exemplary
only, with the true scope and spirit of the invention being
indicated by the following claims. As will be understood by those
of ordinary skill in the art, variations and modifications of each
of the disclosed embodiments, including combinations thereof, can
be made within the scope of this invention as defined by the
following claims.
* * * * *