Electronic devices and processes for forming the same

Abstract

An electronic device includes an array. In one embodiment, a process for forming an electronic device includes the array, which includes electronic components, can include printing one or more layers as a series of segments onto a workpiece. In one embodiment, a process includes printing a layer onto the workpiece and at least one exposed portion of the chuck. In still another embodiment, a printing head is greater than 0.5 mm from the workpiece. In a further embodiment, “hybrid” printing can be used to help form a thicker layer having a relatively thinner width. In a further embodiment, processes can be used to reduce the likelihood of a stitching defect, nonuniformity of a layer across an array, or a combination thereof. A printing apparatus can be modified to achieve more flexibility in liquid compositions, temperatures or other conditions used in printing a layer.

1 - 7 . (canceled) 
     
     
         8 . A process for forming an electronic display device:
 placing a workpiece, having an array, within a printing apparatus;   printing a continuous liquid stream to form a first layer on the array, said first layer having a series of first segments aligned within a portion of the array,   wherein the first segments have a first area between segments and a second area adjacent to the segments, and wherein said printing is continuous across the series of first segments including the first area, but not the adjacent second area, and wherein the first layer is substantially free of a stitching defect.   
     
     
         9 . The process of  claim 8  further comprising:
 printing a continuous liquid stream to form a second layer on the array, said second layer having a series of second segments aligned within a portion of the array, wherein said second segments have a first area between segments and a second area adjacent to the segments, and wherein said printing is continuous across the series of second segments including the first area, but not the adjacent second area, and wherein the first and second layers are located substantially parallel to one another, and wherein the first and second layers are substantially free of a stitching defect. 
 
     
     
         9 . The process of  claim 8 , further comprising:
 printing a continuous liquid stream to form a third layer on the array, said third layer having a series of third segments aligned within a portion of the array, wherein said third segments have a first area between segments and a second area adjacent to the segments, and wherein said printing is continuous across the series of third segments including the first area, but not the adjacent second area, and wherein the first, second and third layers are located substantially parallel to one another, and wherein the first, second and third layers are substantially free of a stitching defect.   
     
     
         11 . The process of  claim 8 ,  9 , or  10  wherein the first area and second area of the respective first, second and/or third segments are substantially the same height. 
     
     
         12 . The process of  claim 8 ,  9  or  10  wherein the first area and second area of the at least two of the first, second and/or third segments have different heights. 
     
     
         13 . The process of  claim 8 ,  9 , or  10  wherein the first segments and second segments have substantially the same surface area. 
     
     
         14 . The process of  claim 9  wherein the first segments and second segments have substantially different surface areas. 
     
     
         15 . The process of claim  10  wherein the first segments, second segments, and third segments have substantially the same surface area. 
     
     
         16 . The process of claim  10  wherein the first segments, second segments, and third segments have substantially different surface areas. 
     
     
         17 . The process of claim  10  wherein the adjacent second area of the first segment is the same surface area as the adjacent second area of the second segment. 
     
     
         18 . The process of claim  10  wherein the second area adjacent to the first segment is common with the second area adjacent to the second segment and a third area adjacent to the second segment is common with the second area adjacent to the third segment. 
     
     
         19 . A electronic device made by the process of  claim 8 ,  9  or  10 .