Method and apparatus for transferring blocks

Abstract

An apparatus and methods of using the same for transferring functional blocks to a substrate. In one exemplary embodiment, a plurality of functional blocks is deposited in a relocating tool having a first plurality of receptor sites. A transfer tool having a plurality of nozzles in aligning with the first plurality of receptor sites removes the plurality of functional blocks from the relocating tool. The transfer tool then deposits the plurality of functional blocks into a second plurality of receptor sites in a substrate. The receptor sites comprise adhesives for securing the functional blocks. Vibration and water are used to facilitate proper delivery of the functional blocks to the receptor sites.

1 . An apparatus for depositing functional blocks into a substrate comprising: 
 a relocating tool having a first plurality of receptor sites having a plurality of functional blocks deposited therein; and    a transfer tool having a plurality of nozzles which are in alignment with said first plurality of receptor sites, said transfer tool being able to remove said plurality of functional blocks from said relocating tool and deposit said plurality of functional blocks into a second plurality of receptor sites in said substrate.    
     
     
         2 . An apparatus for depositing functional blocks into a substrate as in  claim 1  further comprising a vibration device coupling to said transfer tool to agitate said transfer tool as said plurality of functional blocks are being deposited into said second plurality of receptor sites.  
     
     
         3 . An apparatus for depositing functional blocks into a substrate as in  claim 1  further comprising an adhesive dispensing device to dispense adhesive into said second plurality of receptor sites in said substrate before said plurality of functional blocks are deposited into said second plurality of receptor sites.  
     
     
         4 . An apparatus for depositing functional blocks into a substrate as in  claim 1  further comprising a micro liquid dispensing device to dispense droplets of fluid over said second plurality of receptor sites before said plurality of functional blocks are deposited into said second plurality of receptor sites.  
     
     
         5 . An apparatus for depositing functional blocks into a substrate as in  claim 1  further comprising an adhesive dispensing device and a micro liquid dispensing device, said adhesive device to dispense adhesive into said second plurality of receptor sites in said substrate and said micro liquid dispensing device to dispense droplets of fluid over said second plurality of receptor sites before said plurality of functional blocks are deposited into said second plurality of receptor sites.  
     
     
         6 . An apparatus for depositing functional blocks into a substrate as in  claim 1  wherein said second plurality of receptor sites being configured to mate with said plurality of functional blocks.  
     
     
         7 . An apparatus for depositing functional blocks into a substrate as in  claim 6  wherein said plurality of receptor sites and said plurality of functional blocks have any one of a trapezoidal shape, a rectangular shape, a square shape, and a cylindrical shape  
     
     
         8 . An apparatus for depositing functional blocks into a substrate as in  claim 6  wherein said plurality of functional blocks has an asymmetrical shape and said plurality of receptor sites are configured to match said asymmetrical shape.  
     
     
         9 . An apparatus for depositing functional blocks into a substrate as in  claim 1  wherein said transfer tool is further coupled to a vacuum source conveying vacuum to said plurality of nozzles.  
     
     
         10 . An apparatus for depositing functional blocks into a substrate as in  claim 1  wherein all of said first plurality of receptor sites have same dimensions and shapes.  
     
     
         11 . An apparatus for depositing functional blocks into a substrate as in  claim 1  wherein said first plurality of receptor sites comprises of different size and shape receptor sites.  
     
     
         12 . An apparatus for depositing functional blocks into a substrate as in  claim 1  wherein said plurality of nozzles has a dimension that is smaller than a dimension of said plurality of functional blocks.  
     
     
         13 . An apparatus for depositing functional blocks into a substrate as in  claim 1  wherein said plurality of functional blocks are deposited in said transfer tool by an FSA device using a slurry to deposit said plurality of functional blocks into said relocating tool.  
     
     
         14 . An apparatus for depositing functional blocks into a substrate as in  claim 13  further comprising a drying device.  
     
     
         15 . An apparatus for depositing functional blocks into a substrate as in  claim 13  further comprising a curing device.  
     
     
         16 . An apparatus for depositing functional blocks into a substrate comprising: 
 a relocating tool having a first plurality of receptor sites having a plurality of functional blocks deposited therein, said plurality of functional blocks further comprises circuitry components;    a transfer tool having a plurality of nozzles, said transfer tool being able to remove said plurality of functional blocks from said relocating tool and deposit said plurality of functional blocks into said substrate wherein said substrate is made out of a thermoset material and wherein said substrate is hot wherein said plurality of functional blocks are being deposited.    
     
     
         17 . An apparatus for depositing functional blocks into a substrate as in  claim 16  further comprising a heating device capable of heating said substrate to above a softening point.  
     
     
         18 . An apparatus for depositing functional blocks into a substrate as in  claim 17  further comprising a curing device to cure said substrate.  
     
     
         19 . An apparatus for transferring functional blocks comprising: 
 a transfer tool having a plurality of nozzles, said transfer tool to remove a plurality of functional blocks formed on a first substrate from said first substrate;    a transfer station to invert said plurality of functional blocks; and    wherein said transfer tool to pick up inverted functional blocks and deposit said inverted functional blocks onto a second substrate having a plurality of receptor sites.    
     
     
         20 . An apparatus for transferring functional blocks as in  claim 19  further comprising another transfer tool having another plurality of nozzles wherein said another transfer tool to pick up said inverted functional blocks and deposit said inverted functional blocks onto said second substrate having said plurality of receptor sites.  
     
     
         21 . An apparatus for transferring functional blocks as in  claim 19  wherein said plurality of receptor sites has a matching pattern with said plurality of nozzles on said transfer tool.  
     
     
         22 . An apparatus for transferring functional blocks as in  claim 20  wherein said plurality of receptor sites has a matching pattern with said another plurality of nozzles on said another transfer tool.  
     
     
         23 . An apparatus for transferring functional blocks comprising: 
 a transfer tool having a plurality of nozzles, said transfer tool to remove a plurality of functional blocks formed on a first substrate from said first substrate and to transfer said plurality of functional blocks from said first substrate to a functional layer;    a substrate forming station to form a second substrate over said plurality of functional blocks transferred to said functional layer.    
     
     
         24 . An apparatus for transferring functional blocks as in  claim 23  wherein said functional layer is an adhesive anisotropic conducting film that is used to remove said functional blocks from said first substrate.  
     
     
         25 . An apparatus for transferring functional blocks as in  claim 23  wherein said functional layer is a photopatternable layer deposited on a carrier film, wherein said carrier film is removed from said photopatternable layer after said second substrate is formed over said plurality of functional blocks to expose said photopatternable layer.  
     
     
         26 . An apparatus for transferring functional blocks as in  claim 25  further comprising contact vias created in said photopattern able layer for electrical interconnections to said plurality of blocks.  
     
     
         27 . An apparatus as in  claim 26  wherein said functional layer is a photoresist film.  
     
     
         28 . An apparatus for transferring functional blocks comprising: 
 a relocating tool having a first plurality of receptor sites having a plurality of functional blocks deposited therein; and    a transfer tool coupling to a adhesive layer; said transfer tool to transfer said plurality of functional blocks from said relocating tool to a substrate wherein said plurality of functional blocks adhere to said adhesive layer.    
     
     
         29 . An apparatus for transferring functional blocks comprising: 
 a vacuum source coupling to said transfer tool, said vacuum source adheres said adhesive layer to said transfer tool.    
     
     
         30 - 47 . (Canceled)  
     
     
         48 . A method of depositing functional blocks into a substrate comprising: 
 forming a plurality of functional blocks on a first substrate, said plurality of functional blocks further comprises circuitry components;    removing said plurality of functional blocks from said first substrate using a transfer tool having a plurality of nozzles;    inverting said plurality of functional blocks; and    transferring said plurality of functional blocks that are inverted to a second substrate.    
     
     
         49 . A method of depositing functional blocks into a substrate as in  claim 48  wherein said substrate comprises a plurality of receptor sites aligning with said plurality of nozzles and wherein said transferring of said plurality of functional blocks that are inverted includes depositing one of said plurality of functional blocks into one of said second plurality of receptor sites.  
     
     
         50 . A method of depositing functional blocks into a substrate as in  claim 48  wherein said substrate is made out of a thermoplastic or thermoset material and wherein said method further comprising: 
 heating said substrate to above a softening limit of said material to soften said substrate prior to said transferring of said plurality of functional blocks into said substrate.  
 
     
     
         51 . A method of depositing functional blocks into a substrate as in  claim 48  wherein said inverting said plurality of functional blocks comprises: 
 picking up said plurality of functional blocks that are inverted using another transfer tool.  
 
     
     
         52 . A method of depositing functional blocks into a substrate comprising: 
 forming a plurality of functional blocks on a first substrate, said plurality of functional blocks further comprises circuitry components;    removing said plurality of functional blocks from said first substrate using a transfer tool having a plurality of nozzles;    transferring said plurality of functional blocks to a photopatternable layer deposited on a carrier;    forming a second substrate over said plurality of functional blocks deposited on said photopatternable layer; and    removing said carrier to expose said photopatternable layer.    
     
     
         53 . A method of depositing functional blocks into a substrate as in  claim 52  further comprising creating contact vias in said photopatternable layer for electrical interconnections to said plurality of blocks.