Method of manufacturing a distributed light emitting diode flat-screen

Abstract

A novel display screen structure and method of manufacturing such screens for use, for example, in large screen television displays. The process of the present invention is one which can be accomplished with no new materials, no critical geometric requirements such as critical separations and alignments and only low voltage drivers. The combination of these features results in a technology which can be easily scaled to large sizes to provide relatively low-cost large screens for televisions. An important step in a first embodiment of the present invention is the alignment of a large plurality of columnar-shaped light emitting diode slivers in an uncured optical epoxy by applying an electric field through a mixture of such slivers and epoxy and then curing the epoxy to effectively fix the light emitting diode slivers in that aligned configuration. In a second embodiment, the LED slivers are mixed with molten glass which is formed into elongated glass fibers. The fibers are sandwiched between conductive glass plates and heated while an aligning voltage is applied. The light being emitted by such diodes is thereafter controlled by orthogonally directed electrodes at least one of which is optically transparent and which are placed on opposing surfaces of the thin plate-like structure fabricated in accordance with the invention.