Method of assembling displays on substrates
View Patent ↗Various embodiments of methods and systems for designing and constructing displays from multiple light-modulating elements are disclosed. Display elements having different light-modulating and self-assembling characteristics may be used during display assembly and operation.
1. A method of forming a display, comprising:
a) introducing a first set of display elements, each having a first shape, size or surface characteristic and including a light-modulating element of a first type, onto a substrate;
b) inducing relative motion in said display elements in said first set and said substrate sufficient to cause at least a portion of said display elements in said first set to distribute into a first plurality of receptacles on said substrate, said first plurality of receptacles having a first complementary shape, size or surface characteristic that is complementary to said first shape, size or surface characteristic;
c) removing display elements in said first set that have not distributed into receptacles in said first plurality of receptacles;
d) introducing a second set of display elements, having a second shape, size or surface characteristic and including a light-modulating element of a second type, onto said substrate;
e) inducing relative motion in said display elements in said second set and said substrate sufficient to cause at least a portion of said display elements in said second set to distribute into a second plurality of receptacles on said substrate, said second plurality of receptacles having a second complementary shape, size or surface characteristic that is complementary to said second shape, size or surface characteristic;
f) removing display elements in said second set that have not distributed into receptacles in said second plurality of receptacles;
g) connecting display elements distributed into receptacles on said substrate to said substrate; and
h) connecting display elements of said first set to said substrate prior to introducing said second set of display elements onto said substrate.
2. The method of claim 1 , wherein display elements in said first set are configured to have a probability of fitting into receptacles complementary to said second shape, size or surface characteristic that is lower than the probability of display elements in said second set fitting into receptacles complementary to said first shape, size or surface characteristic.
3. The method of claim 1 , wherein display elements having said first shape, size or surface characteristic are of a different size but substantially the same shape as display elements having said second shape, size or surface characteristic.
4. The method of claim 1 , wherein display elements having said first shape, size or surface characteristic are of a different shape but substantially the same size as display elements having said second shape, size or surface characteristic.
5. The method of claim 1 , wherein display elements having said first shape, size or surface characteristic are larger than display elements having said second shape, size or surface characteristic.
6. The method of claim 1 , wherein display elements having said first shape, size or surface characteristic have a different surface characteristic but are substantially the same shape and size as display elements having said second shape, size or surface characteristic.
7. The method of claim 1 , including assisting distribution of a display element of at least one of said first set and said second set into a complementary receptacle on said substrate by at least one of gravity, generation of a body force in the assembly of display elements, bulk acceleration of the display elements, attraction between a display element surface and the interior of a receptacle complementary to said display element, and repulsion of a display element surface from a substrate surface external to said receptacle.
8. The method of claim 1 , including recovering display elements removed from said substrate for later use.
9. The method of claim 1 , including connecting display elements to said substrate by making electrical, magnetic, acoustic or optical connections between said display elements and said substrate.
10. The method of claim 1 , including connecting display elements to adjacent display elements.
11. The method of claim 10 , including connecting display elements to adjacent display elements by forming electrical, magnetic, acoustic or optical connections between said display elements and said substrate.
12. The method of claim 1 , including determining a unique identifier including address information for each said display element following connection of said display element to said substrate through at least one of using circuitry on said display element or using circuitry external to said display element subsequently storing said address information in said display element.
13. The method of claim 1 , wherein introducing display elements in at least one of said first set and said second set includes at least one of spraying said display elements onto said substrate or disposing said display elements onto said substrate in a fluidized medium, a slurry, an emulsion, a suspension, a colloid or a gel.