Multilayered screens with light-emitting stripes for scanning beam display systems

1. A method for making a display screen, comprising:

applying light-emitting materials, that absorb excitation light at an excitation wavelength to emit visible light at wavelengths different from the excitation wavelength, into parallel grooves of a mold so that two adjacent grooves are applied with two different light-emitting materials that emit at two different wavelengths;

controlling a volume of each light-emitting material in each respective groove during the process of applying the light-emitting materials into the mold to partially fill each groove;

applying a liquid material in each groove on top of a respective light-emitting material to fill the groove;

transforming the liquid material into a transparent solid material that attaches to each light-emitting material in each groove;

placing a screen layer on the mold to be in contact with and to engage to the transparent solid material;

lifting the screen layer to lift a stripe formed by the transparent solid material and each light-emitting material out of the mold to form a light-emitting layer of parallel light-emitting stripes; and

applying one or more additional screen layers to the light-emitting layer to form a display screen.

2. The method as in claim 1 , wherein:

the liquid material is a UV-curable material, and

UV light is directed to the liquid material to cure the liquid material in forming the transparent solid material.

3. The method as in claim 1 , wherein:

the liquid material is a heat-curable material, and

heat is applied to the liquid material to cure the liquid material in forming the transparent solid material.

4. The method as in claim 1 , comprising:

after lifting the light-emitting layer of parallel light-emitting stripes out of the mold, coating a metal layer over the light-emitting stripes to cover exposed surfaces of the light-emitting material and the transparent solid material and a surface over the screen layer between two adjacent light-emitting stripes; and

applying a filler material to fill gaps between two adjacent light-emitting stripes;

removing part of the filler material, the metal layer on top of the light-emitting material and a part of the light-emitting material to form a flat surface that exposes the light-emitting material in each light-emitting stripe; and

applying another screen layer over the flat surface.

5. The method as in claim 4 , wherein:

the part of the filler material, the metal layer on top of the light-emitting material and the part of the light-emitting material are removed to leave surface textures on an exposed surface of the light-emitting material so that air gaps are formed between the light-emitting material and the screen layer engaged on the flat surface.

6. The method as in claim 4 , wherein:

the filler material is a black material that absorbs light.

7. The method as in claim 1 , comprising:

after lifting the light-emitting layer of parallel light-emitting stripes out of the mold, filing gaps between adjacent light-emitting stripes with a reflective material to cover exposed surfaces of the light-emitting material and the transparent solid material; and

removing part of the reflective material on top of the light-emitting material and a part of the light-emitting material to form a flat surface that exposes the light-emitting material in each light-emitting stripe; and

applying another screen layer over the flat surface.

8. The method as in claim 7 , wherein:

the part of the reflective material on top of the light-emitting material and the part of the light-emitting material are removed to leave surface textures on an exposed surface of the light-emitting material so that air gaps are formed between the light-emitting material and the screen layer engaged on the flat surface.

9. The method as in claim 1 , comprising:

treating inner surfaces of the grooves in the mold prior to applying the light-emitting materials to facilitate separation of each light-emitting stripe from the mold.

10. The method as in claim 9 , wherein:

the inner surfaces of each groove are coated with a layer of nickel.

11. The method as in claim 9 , wherein:

the inner surfaces of each groove are coated with a layer of a surface lubrication material.

12. The method as in claim 9 , wherein:

the inner surfaces are coated with a layer of nickel.