Mark T Hadley

US Patent:

6420266, Jul 16, 2002

Filed:

Nov 2, 1999

Appl. No.:

09/433605

Inventors:

John Stephen Smith - Berkeley CA
Mark A. Hadley - Newark CA
Jay Tu - Oakland CA

Assignee:

Alien Technology Corporation - Morgan Hill CA

International Classification:

H07L 213065

US Classification:

438692, 438455, 438459, 438665, 438666, 438693, 1566551

Abstract:

Methods for forming elements having a predetermined shape and for assembling the elements. In one example of a method, each of the elements includes a functional component which is disposed on a first face of a first substrate. A layer representing a first portion of the first substrate at a second face of the first substrate is removed, leaving a second portion of the first substrate on the first substrate. The second portion is etched through a first patterned mask on a surface of the second portion. The plurality of elements is then released from the first substrate. The plurality of elements may then be combined with a fluid to form a slurry. In another example of a method, the first face is etched vertically in regions adjacent to the edges of the plurality of elements, and regions below the first face are etched laterally, and then the plurality of elements are released from the substrate. Other methods of creating elements having a predetermined shape are described, and methods of using and/or assembling these elements are also described.

US Patent:

6479395, Nov 12, 2002

Filed:

Nov 2, 1999

Appl. No.:

09/432512

Inventors:

John Stephen Smith - Berkeley CA
Mark A. Hadley - Newark CA
Gordon S. W. Craig - Palo Alto CA
Frank Lowe - Berkeley CA

Assignee:

Alien Technology Corporation - Morgan Hill CA

International Classification:

H01L 21302

US Classification:

438723, 438745, 438756

Abstract:

Methods for forming openings having predetermined shapes in a substrate and apparatuses with these openings. The methods may be used to form assemblies which include the substrate with its openings and elements which are disposed in the openings. In one example of a method, each of the elements include an electrical component and are assembled into one of the openings by a fluidic self assembly process. In an particular example of a method to create such an opening, the substrate is etched through a first patterned mask and is later etched through a second patterned mask. Typically, the second patterned mask is aligned relative to the opening created by etching through the first patterned mask and has an area of exposure which is smaller than an area of exposure through the first patterned mask. In another example of a method, a photosensitive material is exposed through a patterned mask to oblique sources of light such that some of the light impinges into a first portion of the photosensitive material which is under the patterned mask, and the patterned mask and a second portion of the photosensitive material, which is under the patterned mask, is removed. In another example of a method, an opening in a first layer, which comprises silicon dioxide, is formed by depositing a second layer over the first layer and depositing a tungsten layer over the second layer.

US Patent:

6527964, Mar 4, 2003

Filed:

Nov 2, 1999

Appl. No.:

09/432289

Inventors:

John Stephen Smith - Berkeley CA
Mark A. Hadley - Newark CA
Gordon S. W. Craig - Palo Alto CA
Paul F. Nealey - Madison WI

Assignee:

Alien Technology Corporation - Morgan Hill CA

International Classification:

H01L 213065

US Classification:

216 19, 216 17, 216 41, 438107, 438113, 438455, 438456, 252 791

Abstract:

Methods and apparatuses for assembling elements onto a substrate. The surfaces of the elements and/or the substrate are treated and the elements are dispensed over the substrate in a slurry. In one example of the invention, the substrate is exposed to a surface treatment fluid to create a surface on the substrate which has a selected one of a hydrophilic or a hydrophobic nature, and a slurry is dispensed over the substrate. The slurry includes a fluid and a plurality of elements (each of which includes a functional component). Each of the plurality of elements is designed to be received by a receptor region on the substrate. The dispensing of the slurry with the fluid occurs after the substrate is exposed to the surface treatment fluid, and the fluid is the selected one of a hydrophilic or a hydrophobic nature. In another example of the invention, a plurality of elements is exposed to a surface treatment fluid to create surfaces on the elements having a selected one of a hydrophilic or a hydrophobic nature. A slurry is dispensed over a substrate, wherein the slurry contains a fluid and the plurality of elements which are designed to be received by a plurality of receptor regions.

US Patent:

6586338, Jul 1, 2003

Filed:

Apr 23, 2002

Appl. No.:

10/131541

Inventors:

John Stephen Smith - Berkeley CA
Mark A. Hadley - Newark CA
Jay Tu - Oakland CA

Assignee:

Alien Technology Corporation - Morgan Hill CA

International Classification:

H01L 21302

US Classification:

438692, 438406, 438455, 438665, 438666, 438693, 438706, 438733, 438745, 438756

Abstract:

Methods for forming elements having a predetermined shape and for assembling the elements. In one example of a method, each of the elements includes a functional component which is disposed on a first face of a first substrate. A layer representing a first portion of the first substrate at a second face of the first substrate is removed, leaving a second portion of the first substrate on the first substrate. The second portion is etched through a first patterned mask on a surface of the second portion. The plurality of elements is then released from the first substrate. The plurality of elements may then be combined with a fluid to form a slurry. In another example of a method, the first face is etched vertically in regions adjacent to the edges of the plurality of elements, and regions below the first face are etched laterally, and then the plurality of elements are released from the substrate. Other methods of creating elements having a predetermined shape are described, and methods of using and/or assembling these elements are also described.

US Patent:

6590346, Jul 8, 2003

Filed:

Jul 16, 2001

Appl. No.:

09/906627

Inventors:

Mark Alfred Hadley - Newark CA
Randolph Wilfred Eisenhardt - Prunedale CA

Assignee:

Alien Technology Corporation - Morgan Hill CA

International Classification:

G09G 310

US Classification:

3151693, 3151691, 438 22, 438106, 313511, 313521

Abstract:

Method and apparatus for electrical devices. An electronic assembly comprises at least one object having a first electrical circuitry therein. The object is created and separated from a host substrate. The assembly further comprises a receiving substrate having at least one recess. A bottom conducting layer is deposited over the receiving substrate and the recess. The object is then coupled to the receiving substrate such that the object is deposited on the bottom conducting layer and recessed within the first recess and below a surface of the receiving substrate. An insulation layer having a plurality of vias is disposed over the receiving substrate to insulate the bottom conducting layer and the object. A top conducting is deposited over the insulation layer and is making electrical interconnections to the bottom conducting layer and the object through the vias.

US Patent:

6623579, Sep 23, 2003

Filed:

Nov 2, 1999

Appl. No.:

09/432291

Inventors:

John Stephen Smith - Berkeley CA
Mark A. Hadley - Newark CA
Gordon S. W. Craig - Palo Alto CA
Frank Lowe - Berkeley CA

Assignee:

Alien Technology Corporation - Morgan Hill CA

International Classification:

B05D 312

US Classification:

156 736, 156293, 427184, 427346

Abstract:

Methods and apparatuses for assembling a structure onto a substrate. A method according to one aspect of the invention includes dispensing a slurry onto a substrate wherein the slurry includes a first plurality of elements, each of which is designed to mate with a receptor region on said substrate and each of which comprises a functional element, and wherein the slurry also includes a second plurality of elements which are not designed to mate with receptor regions on the substrate. Typically, these second plurality of elements help movement of the first plurality of elements. A method according to another aspect of the invention includes dispensing in a flow having a first direction a slurry onto a substrate, wherein the slurry includes a fluid and a plurality of elements, each of which is designed to mate with a receptor region on the substrate and each of which includes a functional element, and vibrating substrate in a second direction which is substantially perpendicular to the first direction. A method according to another aspect of the invention includes creating a slurry comprising of fluid and a plurality of elements, each of which is designed to mate with a receptor region on the substrate and each of which comprises a functional element, and projecting the slurry through a nozzle toward the substrate. In one particular implementation of this aspect, additional nozzles may be used to provide suction or additional fluid or additional slurry.

US Patent:

6683663, Jan 27, 2004

Filed:

Aug 17, 2001

Appl. No.:

09/932409

Inventors:

Mark A. Hadley - Newark CA
Ann Chiang - Cupertino CA
Gordon S. W. Craig - Palo Alto CA
Jeffrey Jay Jacobsen - Hollister CA
John Stephen Smith - Berkeley CA
Jay Tu - Oakland CA
Roger Green Stewart - Morgan Hill CA

Assignee:

Alien Technology Corporation - Morgan Hill CA

International Classification:

G02F 1136

US Classification:

349 45, 349 42, 349187, 438 34, 438110

Abstract:

Apparatuses and methods for forming displays are claimed. One embodiment of the invention relates to forming an assembly using different sized blocks in either a flexible or rigid substrate.

US Patent:

6927085, Aug 9, 2005

Filed:

Jun 30, 2003

Appl. No.:

10/611142

Inventors:

Mark A. Hadley - Newark CA, US
Ann Chiang - Cupertino CA, US
Gordon S. W. Craig - Palo Alto CA, US
Jeffrey Jay Jacobsen - Hollister CA, US
John Stephen Smith - Berkeley CA, US
Jay Tu - Oakland CA, US
Roger Green Stewart - Morgan Hill CA, US

Assignee:

Alien Technology Corporation - Morgan Hill CA

International Classification:

H01L021/00

US Classification:

438 28, 438107, 438758

Abstract:

Apparatuses and methods for forming displays are claimed. One embodiment of the invention relates to forming an assembly using different sized blocks in either a flexible or rigid substrate.