Fluidic assembly using tunable suspension flow

Embodiments are related to systems and methods for fluidic assembly, and more particularly to systems and methods for increasing the efficiency of fluidic assembly.

FIELD OF THE INVENTION

Embodiments are related to systems and methods for fluidic assembly, and more particularly to systems and methods for increasing the efficiency of fluidic assembly.

BACKGROUND

As some examples, LED displays, LED display components, and arrayed LED devices include a large number of diodes formed or placed at defined locations across the surface of the display or device. Forming or placing such a large number of diodes often results in low throughput of assembled products. Such low throughput increases the cost of an end product.

Hence, for at least the aforementioned reasons, there exists a need in the art for advanced systems and methods for manufacturing LED displays, LED display components, and LED devices.

SUMMARY

Embodiments are related to systems and methods for fluidic assembly, and more particularly to systems and methods for increasing the efficiency of fluidic assembly.

This summary provides only a general outline of some embodiments of the invention. The phrases “in one embodiment,” “according to one embodiment,” “in various embodiments”, “in one or more embodiments”, “in particular embodiments” and the like generally mean the particular feature, structure, or characteristic following the phrase is included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention. Importantly, such phrases do not necessarily refer to the same embodiment. Many other embodiments of the invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

Embodiments are related to systems and methods for fluidic assembly, and more particularly to systems and methods for increasing the efficiency of fluidic assembly.

Various embodiments provide fluidic assembly systems that include a fluidic flow chamber and a flow oscillator. The fluidic flow chamber is formed over a substrate including a plurality of wells and includes a top plate and side walls. The flow oscillator is operable to move a suspension within the fluidic flow chamber in at least a first direction and a second direction. In particular cases, the flow oscillator provides two separately controllable flow controls. The first flow control is the direction of flow (i.e., the first direction or the second direction), and the second flow control is the magnitude of fluid velocity of the suspension in the selected direction within the fluidic flow chamber. The suspension includes a plurality of micro-components and a carrier liquid. In some instances of the aforementioned embodiments, the first direction is away from the flow oscillator and the second direction is toward the flow oscillator. In one or more instances of the aforementioned embodiments, the micro-components are light emitting diodes. In some cases, the flow oscillator is a pump that can generate tunable fluidic flow. As used herein, the phrase “tunable fluidic flow” is used in its broadest sense to mean a flow of fluid that is selectable in either or both of a flow direction and a magnitude of the fluid flow.

In various instances of the aforementioned embodiments, the top plate is at least partially transparent and the system further includes a vision system. The vision system is operable to capture images of the location of micro-components relative to the plurality of wells through the top plate. In some cases, such systems further include an automated oscillation controller operable to: receive the images from the vision system; select a desired direction of flow of the suspension within the fluidic flow chamber and/or a magnitude of fluid velocity within the fluidic flow chamber based at least in part on the images; and command the flow oscillator to produce the selected direction of flow of the suspension and/or the selected magnitude of fluid velocity within the fluidic flow chamber. In particular cases, the vision system includes a microprocessor and a non-transient storage medium that stores instructions executable by the microprocessor to: receive the images from the vision system; select a desired direction of flow of the suspension within the fluidic flow chamber and a magnitude of fluid velocity within the fluidic flow chamber based at least in part on the images; and command the flow oscillator to produce the selected direction of flow of the suspension within the fluidic flow chamber and/or the selected magnitude of fluid velocity within the fluidic flow chamber.

In some instances of the aforementioned embodiments, the system further includes a suspension reservoir operable to hold a portion of the suspension outside of the fluidic flow chamber. In one or more instances of the aforementioned embodiments, the substrate further includes one or more control channels extending a first distance below a top surface of the substrate. At least a subset of the plurality of wells are within one of the one or more control channels and extend as second distance below the top surface of the substrate. In some cases, the control channels are substantially parallel to the first direction and the second direction. In particular instances of the aforementioned embodiments, the top plate includes at least one deflection bar extending down toward the substrate that is substantially perpendicular to the first direction and the second direction.

In various instances of the aforementioned embodiments where the flow oscillator is a first flow oscillator, the system further includes a second flow oscillator operable to move a suspension within the fluidic flow chamber in at least the first direction and the second direction. In other various instances of the aforementioned embodiments where the flow oscillator is a first flow oscillator, the system further includes a second flow oscillator operable to move a suspension within the fluidic flow chamber in at least a third direction and a fourth second direction. The third direction is away from the second flow oscillator and the fourth direction is toward the second flow oscillator, and the third direction and the fourth direction are substantially perpendicular to the first direction and the second direction.

Other embodiments provide methods for fluidic assembly that include: providing a fluidic flow chamber including a top plate, a substrate including a plurality of wells, and side walls; introducing a suspension into the fluidic flow chamber, where the suspension includes a plurality of micro-components and a carrier fluid; commanding a flow oscillator to force movement of the suspension within the fluidic flow chamber alternately in a first direction and a second direction; capturing an image of a location of micro-components relative to the plurality of wells through the top plate; based at least in part on the image, selecting both a magnitude of fluid flow and one of the first direction or the second direction as a tunable fluidic flow; and commanding the flow oscillator to force movement of the suspension within the fluidic flow chamber in accordance with the tunable fluidic flow.

In some instances of the aforementioned embodiments, the flow oscillator is a pump configured to provide a range of tunable fluidic flow. In some cases, the first direction is away from the pump and the second direction is toward the pump. In various instances of the aforementioned embodiments, the micro-components are light emitting diodes. In one or more instances of the aforementioned embodiments, the substrate further includes one or more control channels along a top surface of the substrate. In some cases, the control channels are substantially parallel to the first direction and the second direction. In various cases, the control channels are substantially perpendicular to the first direction and the second direction. In some instances of the aforementioned embodiments, the top plate includes at least one deflection bar extending down toward the substrate that is substantially perpendicular to the first direction and the second direction.

Yet other embodiments provide fluidic assembly systems that include: a fluidic flow chamber, a flow oscillator, a suspension reservoir, a vision system, and an automated oscillation controller. The fluidic flow chamber is formed by a substrate, a top plate, and side walls. The substrate includes a plurality of wells extending below a top surface of the substrate. The flow oscillator is fluidically coupled to the fluidic flow chamber and configured to: pump a suspension within the fluidic flow chamber in a first direction at a first selectable magnitude of fluidic flow toward the flow oscillator, and pump the suspension within the fluidic flow chamber in a second direction at as second selectable magnitude of fluidic flow away from the flow oscillator. The suspension includes a plurality of micro-components and a carrier liquid. The suspension reservoir is fluidically coupled to the fluidic flow chamber and configured to hold a portion of the suspension outside of the fluidic flow chamber. The vision system is configured to capture images of the location of micro-components relative to the plurality of wells through the top plate. The automated oscillation controller configured to: receive the images from the vision system; select one of the first direction and the second direction as a selected direction of flow of the suspension within the fluidic flow chamber based at least in part on the images; select a magnitude of fluidic flow within the fluidic flow chamber as a selected magnitude of fluidic flow based at least in part on the images; and command the flow oscillator to produce the selected direction and the selected magnitude of fluidic flow of the suspension within the fluidic flow chamber.

Turning toFIG. 1a, a fluidic assembly system100capable of moving a suspension110composed of a carrier liquid115and a plurality of micro-components130relative to the surface of a substrate140is shown in accordance with one or more embodiments of the present inventions. In some embodiments, substrate140is formed of a polymer material laminated to the surface of a glass substrate. In particular embodiments, wells142are etched or otherwise formed in the laminate layer. As used herein, the term “well” is used in its broadest sense to mean any surface feature into which only a single micro-component may be deposited. In other embodiments, the substrate is made of glass with wells142directly formed into the glass. Wells142may have flat and vertical surfaces as shown, or they may have bottoms and sides with complex curvatures. As more fully discussed below, wells142may be formed within control channels (not shown) that are etched into (or patterned on top of) the surface of substrate140. In some embodiments the number of micro-components130is substantially larger than the number of wells142. As an example, in one embodiment, the number of micro-components130is more than ten times greater than the number of wells142. Based upon the disclosure provided herein, one of ordinary skill in the art will recognize a variety of materials, processes, and/or structures that may be used to form substrate140. For example, substrate140can be formed of any material or composition compatible with fluidic device processing. This can include, but is not limited to, glass, glass ceramic, ceramic, polymer, metal, or other organic or inorganic materials. As examples, wells142can be defined in a single material forming a surface feature layer when applied to the surface of a base glass sheet. It is also possible for patterned conductor layers to exist between wells142formed in such a surface feature layer and the base glass layer. Substrate140can also be made of multiple layers or combinations of these materials. Substrate140may be a flat, curved, rigid, or flexible structure. In some cases, substrate140may end up being the final device substrate or it may only serve as an assembly substrate to position micro-components130. In the case of an assembly substrate, micro-components130would then be transferred to the final device substrate in subsequent steps. As an example, wells142may be sixty (60) microns (i.e., 10−6meters) in diameter with a depth of five (5) microns, and micro-components may be fifty (50) microns with a height of five (5) microns. Based upon the disclosure provided herein, one of ordinary skill in the art will recognize various sizes of wells142and micro-components130that may be used in relation to different embodiments of the present inventions.

In some embodiments, carrier liquid115is isopropanol. In some cases, a surfactant such as Triton X-100™ may be added to reduce stiction forces between individual micro-components130and/or between micro-components130and surfaces within a fluidic flow chamber. Based upon the disclosure provided herein, one of ordinary skill in the art will recognize a variety of liquids, gasses, and/or liquid and gas combinations that may be used as the carrier liquid. It should be noted that various analysis provided herein is based upon flow in a single, continuous direction or in other cases a relatively simple back-forth motion, but that the flow may be more complex where both the direction and magnitude of fluid velocity can vary over time.

As shown inFIG. 1, micro-components130are of a size and shape capable of fitting into a well142. As used herein, the phrase “micro-component” is used broadly to mean any device capable of dispersement within a carrier liquid to make a suspension. In particular embodiments, micro-components130are light emitting diode (LED) devices. In some cases, the depth of wells142is substantially equal to the height of the micro-components130and the inlet opening of wells142is greater that the width of the micro-components130such that only one micro-component130deposits into any given well142. A fluidic flow chamber of fluidic assembly system100is defined by substrate140, side gaskets120, and a transparent plate190. Side gaskets120may be formed of any elastomeric material capable of forming a liquid seal between transparent plate190and substrate140such that carrier liquid115does not drain on the edges defined by side gaskets120. In one particular embodiment, side gaskets120are formed of polydimethylsiloxane (PDMS). Based upon the disclosure provided herein, one of ordinary skill in the art will recognize a variety of materials that may be used to form side gaskets120in accordance with different embodiments of the present invention. In some embodiments, the height of a fluidic flow chamber between a top surface of substrate140and a bottom surface of transparent plate190is defined by the height of side gaskets120and is between fifty (50 microns and one (1) millimeter.

Transparent plate190may be formed of any material that both allows for a vision system180to make images of micro-components130in relation to substrate140and does not allow carrier liquid115to leak out of the fluidic flow chamber. In some embodiments, transparent plate190is made of glass. In other embodiments, transparent plate190is made of plastic. Based upon the disclosure provided herein, one of ordinary skill in the art will recognize a variety of materials out of which transparent plate190may be formed.

A suspension reservoir151is fluidically coupled to the fluidic flow chamber by an opening154. Suspension reservoir151may be any apparatus capable of holding a volume of suspension110. Opening154is sufficiently large to allow micro-components130to move freely between suspension reservoir151and the fluidic flow chamber. In some embodiments, suspension reservoir151sits off to the side of transparent plate190and is connected by a fluid tube (not shown) connecting suspension reservoir151to the fluidic flow chamber via opening154. In some such embodiments, the fluid tube is connected to opening154using a block of PDMS.

A flow oscillator150is fluidically coupled to the fluidic flow chamber by an opening152. Opening152may be sufficiently large to allow micro-components130to move freely between flow oscillator150and the fluidic flow chamber. Flow oscillator150is a reversible pump that operates to: pull suspension110from the fluidic flow chamber causing additional suspension110to move from suspension reservoir151into the fluidic flow chamber, and push suspension110into the fluidic flow chamber causing suspension110to move from the fluidic flow chamber into suspension reservoir151. The push and pull direction of flow oscillator150is controlled by an automated oscillation controller170. Based upon the disclosure provided herein, one of ordinary skill in the art will recognize a variety of devices that may be used to create the push and pull flow provided by flow oscillator150. For example, flow oscillator150may be implemented by a simple manual syringe or by an automated peristaltic pump. In some embodiments, flow oscillator150sits off to the side of transparent plate190and is connected by a fluid tube (not shown) connecting flow oscillator150to the fluidic flow chamber via opening152. In some such embodiments, the fluid tube is connected to opening154using a block of PDMS. As an example, flow oscillator150may be tunable to produce a magnitude of fluidic flow of between one hundred (100) and two thousand, two hundred (2200) micro liters per minute (i.e., 10-6 liters per minute). Based upon the disclosure provided herein, one of ordinary skill in the art will recognize various flow rates that may be produced in suspension110for use in relation to different embodiments of the present inventions.

Vision system180includes an imaging microscope that is capable of producing images of substrate140through transparent plate190. The produced images may be translated into an X-Y plane representing the surface of substrate140, and provide sufficient resolution to determine that a particular well142is either filled or not filled by a micro-component130, and to show loose micro-components130outside of wells142. Based upon the disclosure provided herein, one of ordinary skill in the art will recognize a variety of imaging systems that may be used in relation to different embodiments. Vision system180provides a continuous stream of images to automated oscillation controller170that in turn modifies the flow of suspension110by controlling flow oscillator150. Automated oscillation controller170may be any circuit or device capable of receiving image data, selecting a desired flow direction and/or magnitude of fluidic flow based upon the received image data, and providing a control corresponding to the selected flow direction and/or magnitude of fluidic flow to flow oscillator150. In some embodiments, automated oscillation controller170is a computer executing control instructions. Based upon the disclosure provided herein, one of ordinary skill in the art will recognize a variety of apparatus that may be used to implement automated oscillation controller170.

Turning toFIG. 1b, a top view101of fluidic assembly system100is shown with a focus on a transparent plate190, flow oscillator150, and suspension reservoir151. Turing toFIG. 1c, a top view102of substrate140is shown with each of wells142shows as dashed lines.

After assembly of fluidic assembly system100, flow oscillator150is started under the direction of automated oscillation controller170to implement a default program of push and pull actions causing a multi-directional flow of the micro-component suspension110over substrate140within the fluidic flow chamber. This default program of push and pull actions applied by flow oscillator150causes what appears to be a stochastic movement of micro-components130relative to wells142in the substrate with some of the wells142being filled by individual micro-components130. Once deposited within a well, the flow of suspension110within the fluidic flow chamber is designed to be low enough to not result in dislodging the already deposited micro-component130.

As micro-components130are being distributed in the default multi-directional flow of suspension110within the fluidic flow chamber, images of micro-components130relative to wells142in substrate140are captured by vision system180. These images are transferred to automated oscillation controller170which decides whether one or more wells142are likely to be filled by a micro-component130if a particular flow direction and/or magnitude of fluid velocity is chosen. Where it is determined that one or more micro-components130are located relative to a given well142such that one of the two flow directions and/or a particular magnitude of fluid velocity is better than the other, the direction and/or magnitude of fluid velocity produced by flow oscillator150is changed to the identified tunable fluidic flow by a command from automated oscillation controller170. By modifying the tunable fluidic flow of the suspension, the direction and/or velocity of a subset of the micro-components130is controlled. This control generally increases the rate at which fluidic assembly of micro-components130into wells142of substrate140is achieved when compared with application of a random flow. The increase in rate is achieved through reducing the randomness of movement of micro-components130relative wells142by controlling flow directions and/or magnitudes of fluidic velocity.

Turning toFIG. 3a, a top view300shows a substrate340over which micro-components are moving and in some cases deposited within wells of the substrate. In this example, a number of wells are already filled with micro-components and are indicated as filled wells342. Other wells are not yet filled and are indicated as empty wells343. A number of micro-components are moving over substrate340and are indicated as free micro-components310. A suspension reservoir370is installed near substrate340, and a flow oscillator350alternatively applies a push force causing a flow of the suspension including free micro-components310generally in a direction347, and a pull force causing a flow of the suspension including free micro-components310generally in a direction346. As shown, a push force may increase the likelihood that free micro-component310gwill deposit in empty well343d, whereas a pull force is less likely to result in a deposition of a free micro-component310into an empty well343. In such a case, the automated oscillation controller sends a signal to flow oscillator350to implement a push force (or to continue with a push force). This command remains until either free micro-component310gwill deposit in empty well343d, or another force direction by flow oscillator350would result in a greater possibility of deposition of a free micro-component310into an empty well343.

Turning toFIG. 2, a flow diagram200shows a method in accordance with some embodiments of the present inventions for fluidic assembly using tunable fluidic flow. Following flow diagram200, a fluidic flow chamber including various fluidic control elements is assembled in relation to a vision monitor (block205). The fluidic control elements include, but are not limited to, a flow oscillator, a suspension reservoir, a substrate, side gaskets, and a transparent plate. Side gaskets are installed on top of the substrate to form walls of the fluidic flow chamber, and the transparent top plate is installed on the walls formed by the side gaskets. This assembly defines the fluidic flow chamber. Next, the flow oscillator is fluidically coupled to the fluidic flow chamber via an opening in the transparent top plate, and the suspension reservoir is fluidically coupled to the fluidic flow chamber via another opening in the transparent top plate. The vision monitor is installed relative to the transparent top plate such that it can capture images of the substrate and micro-components through the transparent top plate. The vision monitor is electrically connected to an automated oscillation controller which itself is electrically connected to the flow oscillator.

The vision monitor is installed relative to the transparent top plate such that it can capture images of the substrate and micro-components through the transparent top plate (block210). The fluidic flow chamber is primed by loading carrier liquid into the suspension reservoir (block215). This carrier liquid flows from the suspension reservoir into the fluidic flow chamber and into the flow oscillator. The flow oscillator can then begin the process of pulling a portion of the carrier liquid from the fluidic flow chamber and reversing to push a portion of the carrier liquid back into the fluidic flow chamber to produce a multi-directional flow within the fluidic flow chamber.

It is then determined whether a grouping of micro-components is to be exposed to sonication (block220). Such sonication involves exposing the grouping of micro-components to sonic energy to cause individual micro-components to separate from one another. Where sonication is desired (block220), the grouping of micro-components is exposed to sound energy (block225). In either case, the grouping of micro-components is loaded into the carrier liquid already in the suspension reservoir to yield a micro-component suspension in the suspension reservoir (block230). The micro-component suspension in the suspension reservoir is agitated to disperse the micro-components within the carrier liquid (block235).

Flow oscillator is started using a default program of push and pull actions causing a multi-directional flow of the micro-component suspension over the substrate within the fluidic flow chamber (block240). This default program of push and pull actions applied by the flow oscillator cause what appears to be a stochastic movement of the micro-components relative to the wells in the substrate with some wells being filled by individual micro-components. Once deposited within a well, the flow of the suspension within the fluidic flow chamber is designed to be low enough to not result in dislodging the already deposited micro-component.

As the micro-components are being distributed in the default multi-directional flow of the suspension within the fluidic flow chamber, images of the micro-components relative to wells in the substrate are captured (block245). These images are transferred to the automated oscillation controller which decides whether one or more wells are likely to be filled by a micro-component if a particular flow direction and/or magnitude of fluid velocity is chosen. Where it is determined that one or more micro-components are located relative to a given well such that one of the two flow directions and/or a particular magnitude of fluid velocity is better than the other, the direction and/or magnitude of fluid velocity produced by the flow oscillator is changed to the identified tunable fluidic flow (block250). By modifying the tunable fluidic flow of the suspension, the direction and/or velocity of a subset of the micro-components is controlled. This control generally increases the rate at which fluidic assembly of the micro-components into the wells of the substrate is achieved when compared with application of a random flow. Further, where one or more micro-components are located very near an unfilled well, the magnitude of the fluid flow in the selected direction may be modified to ease the one or more micro-components toward the respective wells. In some cases, modifying oscillation of the flow oscillator based upon the images of micro-component movement may be limited to modifying a direction of flow generated by the flow oscillator. In other cases, modifying oscillation of the flow oscillator based upon the images of micro-component movement may be limited to modifying a magnitude of the fluid flow generated by the flow oscillator. In yet other cases, modifying oscillation of the flow oscillator based upon the images of micro-component movement includes both changing a direction of flow generated by the flow oscillator and changing a magnitude of the fluid flow generated by the flow oscillator in the selected direction.

Turning toFIG. 3a, top view300shows substrate340over which micro-components are moving and in some cases deposited within wells of the substrate. In this example, a number of wells are already filled with micro-components and are indicated as filled wells342. Other wells are not yet filled and are indicated as empty wells343. A number of micro-components are moving over substrate340and are indicated as free micro-components310. A suspension reservoir370is installed near substrate340, and a flow oscillator350alternatively applies a push force causing a flow of the suspension including free micro-components310generally in a direction347, and a pull force causing a flow of the suspension including free micro-components310generally in a direction346. As shown, a push force may increase the likelihood that free micro-component310gwill deposit in empty well343d, whereas a pull force is less likely to result in a deposition of a free micro-component310into an empty well343. In such a case, the automated oscillation controller sends a signal to flow oscillator350to implement a push force (or to continue with a push force). This command remains until either free micro-component310gwill deposit in empty well343d, or another force direction by flow oscillator350would result in a greater possibility of deposition of a free micro-component310into an empty well343.

Returning toFIG. 2, it is determined whether all wells in the substrate have been filled with micro-components (block255). Turning toFIG. 3b, a top view301shows an example of a completed self assembly where all wells in substrate340are filled and are indicated as filled wells342. Additional free micro-components310remain. Returning again toFIG. 2, where all wells have been filed (block255), self assembly process is completed by flushing excess suspension from the fluidic flow chamber using neat fluid and recycling excess micro-components included in the flushed suspension (block260). Alternatively where all of the wells on the substrate have not yet been filled (block255), the processes of blocks245-255are repeated.

Turning toFIG. 4a, a top view400of a flow oscillator450, a suspension reservoir470, and a substrate440is shown. Substrate440may be used in place of substrate140discussed above in relation toFIG. 1a. Substrate440includes a number of control channels475formed within substrate440to guide free micro-components410toward empty wells443. As shown, wells (shown as filled wells442and empty wells443) are formed within channels470such that a free micro-component410that falls into a given control channel475will tend to move in either a push direction447or a pull direction446toward wells within the channel475. Use of such control channels reduces the randomness of movement of free micro-components410, and generally increases the rate at which fluidic assembly is completed.

Turning toFIG. 4b, a top view401of flow oscillators450a,450b, and suspension reservoirs470a,470bare shown in relation to substrate440. As shown, flow oscillator450aalternatively applies a push force causing a flow of the suspension including free micro-components410generally in a direction447, and a pull force causing a flow of the suspension including free micro-components410generally in a direction446. Flow oscillator450balternatively applies a push force causing a flow of the suspension including free micro-components410generally in a direction448, and a pull force causing a flow of the suspension including free micro-components410generally in a direction449. In operation, flow oscillator450bis first operated to create push and pull forces in directions448,449which are generally perpendicular to control channels475. These gentle push and pull forces increase the likelihood that free micro-components will deposit within one of control channels475. Once the vision system detects free micro-components410within control channels475, flow oscillator450ais operated to create push and pull forces in directions446,447which are generally parallel to control channels475. These gentle push and pull forces increase the likelihood that free micro-components will move along control channels475and deposit within one of empty wells443located along control channels475. The arrangement of substrate440and flow oscillators450may be used in place of substrate140and flow oscillator150discussed above in relation toFIG. 1a. Again,FIGS. 4cand 4dshow an example channel depth relative to well depth in substrate440.

Turning toFIG. 4c, a cross sectional view490of an well492within a control channel494is shown. Of note, control channel494extends only slightly below an upper surface496of a substrate, while well492extends to a greater depth. In some cases, as depicted inFIG. 4d, the depth of well492is greater than the height of a micro-component498such that once micro-component498deposits within well492it is difficult to displace it from the well. In contrast, the depth of control channel494is substantially less than that of well492, and is sufficiently deep that it is most likely for the micro-component to continue moving within control channel475.

Turning toFIG. 5, a top view500of multiple flow oscillators550and suspension reservoirs570disposed in relation to a single substrate540is shown. The arrangement of substrate540and flow oscillators550may be used in place of substrate140and flow oscillator150discussed above in relation toFIG. 1a. As shown, each of flow oscillators550a,550b,550calternatively applies a push force causing a flow of the suspension including free micro-components510generally in a direction547, and a pull force causing a flow of the suspension including free micro-components510generally in a direction546. By using multiple flow oscillators550aligned as shown in top view500, a more uniform flow is possible across the entire surface of substrate540when compared with the flow generated using a single flow oscillator as discussed above in relation toFIGS. 3a-3b. Further, in some embodiments, each of flow oscillators550a,550b,550care independently controllable by an automated oscillation controller (e.g., automated oscillation controller170ofFIG. 1). By allowing independent control of flow oscillators550a,550b,550c, additional control of flows around selected free micro-components510may be generated. It should be noted that while the embodiment ofFIG. 5is shown using three flow oscillators550in parallel, that more or fewer than three flow oscillators may be used in relation to different embodiments. The number of flow oscillators550may be scaled as a function of the size of substrate540and the desired level of flow control. The desired level of flow control should avoid dead zones near relevant areas of substrate including wells. Further, the angle of inlets and outlets to/from flow oscillators550and suspension0reservoirs570may be adjusted to in order to reduce or eliminate aggregations of micro-components during loading or active flow periods.

Turning toFIG. 6, a top view600of multiple flow oscillators650surrounding a substrate640with multiple reservoirs670disposed over substrate640is shown. The arrangement of substrate640, flow oscillators650, and suspension reservoirs670may be used in place of substrate140, flow oscillator150, and suspension reservoir151discussed above in relation toFIG. 1a. As shown, each of flow oscillators650a,650b,650c alternatively applies a push force causing a flow of the suspension including free micro-components610generally in a direction647, and a pull force causing a flow of the suspension including free micro-components610generally in a direction646; and each of flow oscillators650d,650e,650falternatively applies a push force causing a flow of the suspension including free micro-components610generally in a direction646, and a pull force causing a flow of the suspension including free micro-components610generally in a direction647. By using multiple flow oscillators650aligned as shown in top view600, a more uniform flow is possible across the entire surface of substrate640when compared with the flow generated using a single flow oscillator as discussed above in relation toFIGS. 3a-3b, or the one sided distribution of flow oscillators discussed above in relation toFIG. 5. Further, in some embodiments, each of flow oscillators650a,650b,650c,650d,650e,650fare independently controllable by an automated oscillation controller (e.g., automated oscillation controller170ofFIG. 1). By allowing independent control of flow oscillators650a,650b,650c,650d,650e,650f, additional control of flows around selected free micro-components610may be generated. It should be noted that while the embodiment ofFIG. 6is shown using six flow oscillators650, that more or fewer than six flow oscillators may be used in relation to different embodiments. The number of flow oscillators650and suspension reservoirs670may be scaled as a function of the size of substrate640and the desired level of flow control. The desired level of flow control should avoid dead zones near relevant areas of substrate including wells. Further, the angle of inlets and outlets to/from flow oscillators650and suspension reservoirs670may be adjusted to in order to reduce or eliminate aggregations of micro-components during loading or active flow periods.

Turning toFIGS. 7a-7b, a particular implementation of a transparent plate790is depicted that may be used in place of transparent plate190discussed above in relation toFIG. 1a.FIGS. 7a-7bshow a top view700and a cross sectional view701of transparent plate790including deflection bars792,794,796extending downward a distance798form a bottom surface of transparent plate790. A flow oscillator750and a suspension reservoir770are shown in relation to transparent plate790. As push and pull forces are applied by flow oscillator750one or more micro-components brush up against the bottom surface of transparent plate790as they are moved with the suspension. As the micro-components brush up against transparent plate790they are deflected downward by deflection bars792,794,796toward the surface of an underlying substrate. In some embodiments, distance798is between forty (40) microns and nine hundred fifty (950) microns. Based upon the disclosure provided herein, one of ordinary skill in the art will recognize a variety of lengths for distance798.

Turning toFIG. 8, a top view800of a particular implementation of side walls880,884each including an uneven edge extending into a fluidic flow chamber810toward another of the side walls that may be used in place of the side gaskets120discussed above in relation toFIG. 1a. As shown, side walls880,884extend in a direction defining fluidic flow chamber810between a flow oscillator850and a suspension reservoir870. An inner edge882of sidewall880includes a number of serrations862extending toward sidewall884. Similarly, an inner edge886of sidewall884includes a number of serrations866extending toward sidewall880. As push and pull forces are applied by flow oscillator850one or more micro-components brush up against serrations862,866as they are moved with the suspension. As the micro-components brush up against serrations862,866they are deflected toward a center region of fluidic flow chamber810.

It should be noted that in some cases, chemistry such as oxidization can be used to modify or/and pattern the surfaces of the micro-components and/or the substrate including wells so that they are both hydrophilic (e.g., water contact angle <25 degrees) or at selective locations on the substrate. One of ordinary skill in the art will recognize various advantages achievable through use of different embodiments of the inventions. As just some of many advantages, lower display costs are possible as a significant cost of manufacturing a micro LED display is the time it takes to assemble micro-components into a substrate. As some embodiments offer enhancements to the rate at which a display may be assembled, the time to assemble and therefore the cost of assembly is reduced.

In conclusion, the invention provides novel systems, devices, methods and arrangements for fluidic assembly. While detailed descriptions of one or more embodiments of the invention have been given above, various alternatives, modifications, and equivalents will be apparent to those skilled in the art without varying from the spirit of the invention. For examples, while some embodiments are discussed in relation to displays, it is noted that the embodiments find applicability to devices other than displays. Therefore, the above description should not be taken as limiting the scope of the invention, which is defined by the appended claims.