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.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/214,740, filed Aug. 9, 2002, now U.S. Pat. No. 6,764,367 entitled Liquid Manufacturing Processes for Panel Layer Fabrication, which is a continuation-in-part of application Ser. No. 09/697,344, filed Oct. 27, 2000, now U.S. Pat. No. 6,612,889, entitled Method for Making a Light-Emitting Panel, and is related to the following co-owned applications: Ser. No. 09/697,346, now U.S. Pat. No. 6,545,422, filed Oct. 27, 2000, entitled A Socket for Use with a Micro-Component in a Light-Emitting Panel; Ser. No. 09/697,358, filed Oct. 27, 2000, entitled: A Micro-Component for Use in a Light-Emitting Panel; Ser. No. 09/697,498, filed Oct. 27, 2000, now U.S. Pat. No. 6,620,012, entitled A Method for Testing a Light-Emitting Panel and the Components Therein; Ser. No. 09/697,345, filed Oct. 27, 2000, now U.S. Pat. No. 6,570,335, entitled A Method and System for Energizing a Micro-Component In a Light-Emitting Panel; Ser. No. 10/214,769, filed Aug. 9, 2002, entitled Use of Printing and Other Technology for Micro-Component Placement Ser. No. 10/214,716, filed Aug. 9, 2002, entitled Method of On-Line Testing of a Light-Emitting Panel Ser. No. 10/214,764, filed Aug. 9, 2002, entitled Method and Apparatus for Addressing Micro-Components in a Plasma Display Panel; and Ser. No. 10/214,768, filed Aug. 9, 2002, entitled Design, Fabrication, Conditioning, and Testing of Micro-Components for Use in a Light-Emitting Panel. Each of the above-identified applications is incorporated herein by reference in its entirety.
There is disclosed electrode configurations for a plasma display panel (PDP) device having one or more substrates and a multiplicity of pixels or sub-pixels that are defined by a hollow plasma-shell filled with an ionizable gas. As used herein plasma-shell includes plasma-disc, plasma-dome, and plasma-sphere. The invention is described with reference to a plasma-dome, but other plasma-shells may be used including plasma-disc and plasma-sphere. The plasma-dome has a dome and an opposing flat side such as a dome top and a flat bottom or vice versa. One or more other sides or edges may also be flat or domed. Two or more addressing electrodes are in electrical contact with each plasma-dome, at least one electrode being in contact with a side of the plasma-dome that is not flat. The PDP may include inorganic and/or organic luminescent substances that are excited by the gas discharge within each plasma-dome. The luminescent substance may be located on an exterior and/or interior surface of the plasma-dome and/or incorporated into the shell of the plasma-dome. Up-conversion (Stokes) and down-conversion (Anti-Stokes) phosphor materials may be used. The PDP substrate(s) may be rigid, flexible, or semi-flexible with a flat, curved, or irregular surface.
There is disclosed a positive column gas discharge plasma display device comprising one or more ionizable gas filled elongated Plasma-tubes. The display may be a dual substrate or a single substrate device. One or more substrates may be of a flexible material. The ionizable gas produces photons in the UV, IR, and/or visible range during gas discharge. The photons may excite one or more luminescent materials located on or in close proximity to one or more Plasma-tubes. The plasma display device may contain at least one Plasma-shell filled with an ionizable gas that produces photons in the UV, IR, and/or visible range during gas discharge. Plasma-shell includes Plasma-disc, Plasma-dome and Plasma-sphere.
There is disclosed a process for fabricating a positive column gas discharge plasma display device comprising one or more ionizable gas filled elongated Plasma-tubes. The display may be a dual substrate or a single substrate device. The ionizable gas typically produces photons in the UV, IR, and/or visible range during gas discharge. The photons may excite one or more phosphors located on or in close proximity to one or more Plasma-tubes. The plasma display device may contain at least one Plasma-shell that produces photons in the UV, IR, and/or visible range during gas discharge. Plasma-shell includes Plasma-disc, Plasma-dome and Plasma-sphere.
A PDP constructed out of one or more Plasma-shells with a luminescent substance(s) located in close proximity to each Plasma-shell. The luminescent substance comprises a combination of an organic luminescent substance and an inorganic luminescent substance. The combination may be a mixture of organic and inorganic substances. Layers of organic and inorganic substances may be used. Each Plasma-shell is a hollow geometric body filled with an ionizable gas at a suitable pressure. Photons from the gas discharge inside the Plasma-shell excite the luminescent substance. In one embodiment the luminescent substance is located on the external surface of the Plasma-shell. In another embodiment, the luminescent substance is located inside the Plasma-shell. Plasma-shell includes Plasma-sphere, Plasma-disc, and Plasma-dome. The Plasma-shell may be used in combination with a Plasma-tube.
Plasma-shells filled with ionizable gas are positioned on or within a rigid or flexible substrate. Each Plasma-shell is electrically connected to at least two electrical conductors such as electrodes with an electrically conductive bonding substance to form an electrical connection to each electrode. The electrically conductive bonding substance may comprise a pad connected to both the Plasma-shell and an electrode.
