Patent ID: 6476886
Filing Date: 2002-11-05
Classification: G02F

Abstract:
A method for assembling a plurality of reflective microdisplay tiles into a tiled, flat-panel display, the projected image of which display having visually imperceptible seams in reflection, the steps comprising:a) providing a plurality of reflective monolithic microdisplay tiles, each tile having a front, active face, a rear, mounting face, at least one inner, precision finished edge, each of said microdisplay tiles comprising an array of pixels having a predetermined pixel pitch and having a semiconductor integrated circuit backplane embedded therein; b) laterally arranging said plurality of microdisplay tiles adjacent one another with said at least one inner, precision finished edge of a first one of said plurality of microdisplay tiles adjacent said at least one precision finished edge of a second one of said plurality of microdisplay tiles; c) releasably attaching said front, active faces of said plurality of microdisplay tiles to an optically flat carrier; d) after said laterally arranging step (b) and said releasably attaching step (c), applying a filling material to said rear faces of said plurality of tiles, if required, to fill any gaps between said inner, precision finished edges of said microdisplay tiles; e) after completing said releasably attaching step (c), polishing said rear, mounting face of each of said plurality of microdisplay tiles, if required; f) after completing said polishing step (e), attaching a common substrate to said rear, mounting faces of said plurality of microdisplay tiles; and g) after said attaching step (f), removing said plurality of microdisplay tiles from said optically flat carrier and polishing said front active faces of each of said plurality of microdisplay tiles to a precision of less than approximately 100 nM.