Patents by Inventor David MASSOUBRE

David MASSOUBRE has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20210111319
    Abstract: Techniques disclosed herein relate to micro light emitting diodes (micro-LEDs) for a display system. A display system includes an array of micro light emitting diodes (micro-LEDs), an array of output couplers optically coupled to the array of micro-LEDs and configured to extract light emitted by respective micro-LEDs in the array of micro-LEDs, a waveguide display, and display optics configured to couple the light emitted by the array of micro-LEDs and extracted by the array of output couplers into the waveguide display. Each output coupler in the array of output couplers is configured to direct a chief ray of the light emitted by a respective micro-LED in the array of micro-LEDs to a different respective direction.
    Type: Application
    Filed: April 3, 2020
    Publication date: April 15, 2021
    Inventors: Stephan Lutgen, François Gérard Franck Olivier, Vasily Zabelin, William Padraic Henry, Markus Broell, Thomas Lauermann, David Massoubre, Daniel Bryce Thompson, Michael Grundmann
  • Patent number: 10942378
    Abstract: A pupil-replicating waveguide suitable for operation with a coherent light source is disclosed. A waveguide body has opposed surfaces for guiding a beam of image light. An out-coupling element is disposed in an optical path of the beam for out-coupling portions of the beam at a plurality of spaced apart locations along the optical path. Electrodes are coupled to at least a portion of the waveguide body for modulating an optical path length of the optical path of the beam to create time-varying phase delays between the portions of the beam out-coupled by the out-coupling element.
    Type: Grant
    Filed: June 2, 2020
    Date of Patent: March 9, 2021
    Assignee: FACEBOOK TECHNOLOGIES, LLC
    Inventors: Andrew Maimone, Andrew Ouderkirk, Hee Yoon Lee, Ningfeng Huang, Maxwell Parsons, Scott Charles McEldowney, Babak Amirsolaimani, Pasi Saarikko, Wanli Chi, Giuseppe Calafiore, Alexander Koshelev, Barry David Silverstein, Lu Lu, Wai Sze Tiffany Lam, Gang Li, Stephan Lutgen, Francois Olivier, David Massoubre
  • Publication number: 20210036184
    Abstract: A emitting diode (LED) includes an epitaxial structure defining a base and a mesa on the base. The base defines a light emitting surface of the LED and includes current spreading layer. The mesa includes a thick confinement layer, a light generation area on the thick confinement layer to emit light, a thin confinement layer on the light generation area, and a contact layer on the thin confinement layer, the contact layer defining a top of the mesa. A reflective contact is on the contact layer to reflect a portion of the light emitted from the light generation area, the reflected light being collimated at the mesa and directed through the base to the light emitting surface. In some embodiments, the epitaxial structure grown on a non-transparent substrate. The substrate is removed, or used to form an extended reflector to collimate light.
    Type: Application
    Filed: October 20, 2020
    Publication date: February 4, 2021
    Inventors: Stephan Lutgen, David Massoubre
  • Patent number: 10910514
    Abstract: Techniques related to molded etch masks are disclosed. Etch masks can be formed based on pressing a mold against a layer of pliable masking material applied to a surface of an epitaxial layered structure. The epitaxial layered structure includes a first semiconductor layer, a second semiconductor layer, and a light-emitting layer between the first and second semiconductor layers. The epitaxial layered structure is etched using the molded etch masks to form etched structures. The etched structures may be optical structures that modify light emitted through the surface or epitaxial mesas that collimate light within the epitaxial layered structure.
    Type: Grant
    Filed: December 21, 2018
    Date of Patent: February 2, 2021
    Assignee: FACEBOOK TECHNOLOGIES, LLC
    Inventors: Daniel Brodoceanu, David Massoubre, Karsten Moh
  • Patent number: 10878733
    Abstract: A method for manufacturing a display element comprising a plurality of pixels, each comprising a plurality of sub-pixels. The method comprises undertaking, using a pick up tool, a first placement cycle (1908) comprising picking up a plurality of first, untested LED dies and placing them on a display substrate at locations corresponding to the plurality of pixels, testing (1912) the first LED emitters on the display substrate to determine one or more locations of non-functional first LED emitters, selecting one or more second tested LED dies based on a result of the test, configuring the selected one or more second LED dies to enable their pick up and placement on the display substrate and undertaking, using the PUT, a second placement cycle (2008) comprising picking up the selected one or more second LED dies and placing them on the display substrate at the determined locations of the non-functional first LED emitters.
    Type: Grant
    Filed: September 2, 2016
    Date of Patent: December 29, 2020
    Assignee: Facebook Technologies, LLC
    Inventors: Padraig Hughes, Joseph O'Keeffe, Celine Oyer, William Henry, David Massoubre, Pooya Saketi
  • Patent number: 10847675
    Abstract: A emitting diode (LED) includes an epitaxial structure defining a base and a mesa on the base. The base defines a light emitting surface of the LED and includes current spreading layer. The mesa includes a thick confinement layer, a light generation area on the thick confinement layer to emit light, a thin confinement layer on the light generation area, and a contact layer on the thin confinement layer, the contact layer defining a top of the mesa. A reflective contact is on the contact layer to reflect a portion of the light emitted from the light generation area, the reflected light being collimated at the mesa and directed through the base to the light emitting surface. In some embodiments, the epitaxial structure grown on a non-transparent substrate. The substrate is removed, or used to form an extended reflector to collimate light.
    Type: Grant
    Filed: October 10, 2019
    Date of Patent: November 24, 2020
    Assignee: Facebook Technologies, LLC
    Inventors: Stephan Lutgen, David Massoubre
  • Patent number: 10840418
    Abstract: Systems and methods for fabricating parabolic LEDs are provided. The parabolic shape of the LEDs is precisely-controlled and highly-uniform across a substrate. By precisely controlling the shape, and providing a high-uniformity across the substrate, the luminance and process yield of the LEDs is enhanced. The precise-control and high-uniformity of the shape is enabled via a precisely-shaped and highly-uniform mask formed on the substrate. The ability to precisely-control both the shape and uniformity the mask is achieved by forming the mask utilizing three-dimensional (3D) patterning and/or machining methods. The mask includes a precisely-shaped boss with the same shape as the LED, and a cylindrical protrusion extending beyond the boss. The combination of the boss and cylindrical protrusion allows for the mask to be over-etched, without significantly effecting the shape of the LED. Thus, any non-uniformities etching process do not decrease the luminance, nor uniformity, of the LEDs.
    Type: Grant
    Filed: May 28, 2019
    Date of Patent: November 17, 2020
    Assignee: Facebook Technologies, LLC
    Inventors: David Massoubre, Daniel Brodoceanu, Oscar Torrents Abad, Vaishali Chopra
  • Patent number: 10811575
    Abstract: Techniques related to laser lift-off masks are disclosed. In some embodiments, masking material is applied to a substrate that is attached to a plurality of semiconductor device sets. More specifically, the masking material is applied to one or more regions of the substrate between the semiconductor device sets. When the semiconductor device sets are embedded in a filling material, the masking material may be situated between the substrate and the filling material. Thus, transmitting light through the substrate toward the semiconductor device sets causes the substrate to become detached from the semiconductor device sets. However, the light is at least partially occluded by the masking material.
    Type: Grant
    Filed: July 30, 2018
    Date of Patent: October 20, 2020
    Assignee: FACEBOOK TECHNOLOGIES, LLC
    Inventors: Daniel Brodoceanu, David Massoubre, James Small, Oscar Torrents Abad, Patrick Joseph Hughes
  • Patent number: 10790408
    Abstract: A micro-light emitting diode (LED) is manufactured using a lift-off substrate that is removed using a laser-lift-off process. A method for manufacturing the LED may include forming an epitaxial structure of the LED on a growth substrate, and attaching an open side of the epitaxial structure with a gallium-based layer and a lift-off substrate, the gallium-based layer between the epitaxial structure and the lift-off substrate. The growth substrate is separated from the epitaxial structure, and the epitaxial structure may be processed into the LED. Light is applied to the gallium-based layer through the lift-off substrate to debond the second portion of the gallium-based layer and the lift-off substrate. The lift-off substrate is separated from the second portion of the gallium-based layer to expose a light emitting surface of the LED on the second portion of the gallium-based layer.
    Type: Grant
    Filed: March 22, 2019
    Date of Patent: September 29, 2020
    Assignee: Facebook Technologies, LLC
    Inventor: David Massoubre
  • Publication number: 20200292851
    Abstract: A pupil-replicating waveguide suitable for operation with a coherent light source is disclosed. A waveguide body has opposed surfaces for guiding a beam of image light. An out-coupling element is disposed in an optical path of the beam for out-coupling portions of the beam at a plurality of spaced apart locations along the optical path. Electrodes are coupled to at least a portion of the waveguide body for modulating an optical path length of the optical path of the beam to create time-varying phase delays between the portions of the beam out-coupled by the out-coupling element.
    Type: Application
    Filed: June 2, 2020
    Publication date: September 17, 2020
    Inventors: Andrew Maimone, Andrew Ouderkirk, Hee Yoon Lee, Ningfeng Huang, Maxwell Parsons, Scott Charles McEldowney, Babak Amirsolaimani, Pasi Saarikko, Wanli Chi, Giuseppe Calafiore, Alexander Koshelev, Barry David Silverstein, Lu Lu, Wai Sze Tiffany Lam, Gang Li, Stephan Lutgen, Francois Olivier, David Massoubre
  • Patent number: 10741717
    Abstract: Embodiments relate to a micro light-emitting-diode (?LED) fabricated using a self-aligned process. To fabricate the ?LED, a metal layer is deposited on a p-type semiconductor. The p-type semiconductor is on an n-type semiconductor and the n-type semiconductor is on a top side of a substrate. The metal layer is patterned to define a p-metal. The p-type semiconductor is etched using the p-metal as an etch mask. Similarly, the n-type semiconductor is etched using the p-metal and the p-type semiconductor as an etch mask. A negative photoresist layer is deposited over the patterned p-metal and the p-type semiconductor. The negative photoresist is then exposed from the back side of the substrate, thus exposing the regions of the negative photoresist that are not masked by the p-metal. The negative photoresist is then developed to expose the p-metal.
    Type: Grant
    Filed: March 18, 2019
    Date of Patent: August 11, 2020
    Assignee: Facebook Technologies, LLC
    Inventors: Celine Claire Oyer, David Massoubre, Tilman Zehender
  • Patent number: 10705353
    Abstract: A pupil-replicating waveguide suitable for operation with a coherent light source is disclosed. A waveguide body has opposed surfaces for guiding a beam of image light. An out-coupling element is disposed in an optical path of the beam for out-coupling portions of the beam at a plurality of spaced apart locations along the optical path. Electrodes are coupled to at least a portion of the waveguide body for modulating an optical path length of the optical path of the beam to create time-varying phase delays between the portions of the beam out-coupled by the out-coupling element.
    Type: Grant
    Filed: December 18, 2018
    Date of Patent: July 7, 2020
    Assignee: Facebook Technologies, LLC
    Inventors: Andrew Maimone, Andrew Ouderkirk, Hee Yoon Lee, Ningfeng Huang, Maxwell Parsons, Scott Charles McEldowney, Babak Amirsolaimani, Pasi Saarikko, Wanli Chi, Giuseppe Calafiore, Alexander Koshelev, Barry David Silverstein, Lu Lu, Wai Sze Tiffany Lam, Gang Li, Stephan Lutgen, Francois Olivier, David Massoubre
  • Publication number: 20200192130
    Abstract: A pupil-replicating waveguide suitable for operation with a coherent light source is disclosed. A waveguide body has opposed surfaces for guiding a beam of image light. An out-coupling element is disposed in an optical path of the beam for out-coupling portions of the beam at a plurality of spaced apart locations along the optical path. Electrodes are coupled to at least a portion of the waveguide body for modulating an optical path length of the optical path of the beam to create time-varying phase delays between the portions of the beam out-coupled by the out-coupling element.
    Type: Application
    Filed: December 18, 2018
    Publication date: June 18, 2020
    Inventors: Andrew Maimone, Andrew Ouderkirk, Hee Yoon Lee, Ningfeng Huang, Maxwell Parsons, Scott Charles McEldowney, Babak Amirsolaimani, Pasi Saarikko, Wanli Chi, Giuseppe Calafiore, Alexander Koshelev, Barry David Silverstein, Lu Lu, Wai Sze Tiffany Lam, Gang Li, Stephan Lutgen, Francois Olivier, David Massoubre
  • Publication number: 20200127159
    Abstract: A emitting diode (LED) includes an epitaxial structure defining a base and a mesa on the base. The base defines a light emitting surface of the LED and includes current spreading layer. The mesa includes a thick confinement layer, a light generation area on the thick confinement layer to emit light, a thin confinement layer on the light generation area, and a contact layer on the thin confinement layer, the contact layer defining a top of the mesa. A reflective contact is on the contact layer to reflect a portion of the light emitted from the light generation area, the reflected light being collimated at the mesa and directed through the base to the light emitting surface. In some embodiments, the epitaxial structure grown on a non-transparent substrate. The substrate is removed, or used to form an extended reflector to collimate light.
    Type: Application
    Filed: October 10, 2019
    Publication date: April 23, 2020
    Inventors: Stephan Lutgen, David Massoubre
  • Patent number: 10600823
    Abstract: A method for manufacturing a display element comprising a plurality of pixels, each comprising a plurality of subpixels. The method comprises undertaking, using a pick up tool, a first placement cycle (1908) comprising picking up a plurality of first, untested LED dies and placing them on a display substrate at locations corresponding to the plurality of pixels, testing (1912) the first LED emitters on the display substrate to determine one or more locations of non-functional first LED emitters, selecting one or more second tested LED dies based on a result of the test, configuring the selected one or more second LED dies to enable their pick up and placement on the display substrate and undertaking, using the PUT, a second placement cycle (2008) comprising picking up the selected one or more second LED dies and placing them on the display substrate at the determined locations of the nonfunctional first LED emitters.
    Type: Grant
    Filed: March 12, 2018
    Date of Patent: March 24, 2020
    Assignee: Facebook Technologies, LLC
    Inventors: Padraig Hughes, Joseph O'Keeffe, Celine Oyer, William Henry, David Massoubre, Pooya Saketi
  • Patent number: 10573781
    Abstract: A light emitting diode (LED) is manufactured using a process in which hydrogen diffuses out of a p-doped semiconductor layer via an exposed side wall of the p-doped semiconductor layer. The process includes forming a light generation layer on a base semiconductor layer and forming the p-doped semiconductor layer on the light generation layer. A tunnel junction layer is formed on the p-doped semiconductor layer and a contact layer is formed on the junction layer. The process also includes etching through at least the contact layer, the tunnel junction layer, and the p-doped semiconductor layer to expose the side wall of the p-doped semiconductor layer and enabling hydrogen to diffuse out of the p-doped semiconductor layer at least partially through the exposed side wall.
    Type: Grant
    Filed: August 27, 2018
    Date of Patent: February 25, 2020
    Assignee: Facebook Technologies, LLC
    Inventors: Anneli Munkholm, David Massoubre
  • Publication number: 20200035880
    Abstract: Techniques related to laser lift-off masks are disclosed. In some embodiments, masking material is applied to a substrate that is attached to a plurality of semiconductor device sets. More specifically, the masking material is applied to one or more regions of the substrate between the semiconductor device sets. When the semiconductor device sets are embedded in a filling material, the masking material may be situated between the substrate and the filling material. Thus, transmitting light through the substrate toward the semiconductor device sets causes the substrate to become detached from the semiconductor device sets. However, the light is at least partially occluded by the masking material.
    Type: Application
    Filed: July 30, 2018
    Publication date: January 30, 2020
    Inventors: Daniel Brodoceanu, David Massoubre, James Small, Oscar Torrents Abad, Patrick Joseph Hughes
  • Patent number: 10522709
    Abstract: LEDs are manufactured on a substrate layer and picked and placed using a pick-up tool (PUT) onto a target substrate. The PUT typically attaches to an LED via an elastomer layer deposited on a surface of the LED. A given batch of manufactured LEDs may contain operational LEDs as well as non-operational LEDs. In order to separate the operational and non-operational LEDs, the LEDs are placed on a unidirectional conductive film. A photo-curable polymer is deposited on a surface of each LED. A voltage difference is applied across the electrodes of each LED via the unidirectional conductive film, causing the operational LEDs to emit light and cure the photo-curable polymer to form an elastomer layer, while the polymer deposited on the non-operational LEDs will not cure. As such, the PUT will be able to pick up the operational LEDs, while being unable to pick up the non-operational LEDs.
    Type: Grant
    Filed: December 5, 2017
    Date of Patent: December 31, 2019
    Assignee: Facebook Technologies, LLC
    Inventors: Pooya Saketi, Patrick Joseph Hughes, David Massoubre
  • Patent number: 10483430
    Abstract: A emitting diode (LED) includes an epitaxial structure defining a base and a mesa on the base. The base defines a light emitting surface of the LED and includes current spreading layer. The mesa includes a thick confinement layer, a light generation area on the thick confinement layer to emit light, a thin confinement layer on the light generation area, and a contact layer on the thin confinement layer, the contact layer defining a top of the mesa. A reflective contact is on the contact layer to reflect a portion of the light emitted from the light generation area, the reflected light being collimated at the mesa and directed through the base to the light emitting surface. In some embodiments, the epitaxial structure grown on a non-transparent substrate. The substrate is removed, or used to form an extended reflector to collimate light.
    Type: Grant
    Filed: May 1, 2018
    Date of Patent: November 19, 2019
    Assignee: Facebook Technologies, LLC
    Inventors: Stephan Lutgen, David Massoubre
  • Publication number: 20190341521
    Abstract: A emitting diode (LED) includes an epitaxial structure defining a base and a mesa on the base. The base defines a light emitting surface of the LED and includes current spreading layer. The mesa includes a thick confinement layer, a light generation area on the thick confinement layer to emit light, a thin confinement layer on the light generation area, and a contact layer on the thin confinement layer, the contact layer defining a top of the mesa. A reflective contact is on the contact layer to reflect a portion of the light emitted from the light generation area, the reflected light being collimated at the mesa and directed through the base to the light emitting surface. In some embodiments, the epitaxial structure grown on a non-transparent substrate. The substrate is removed, or used to form an extended reflector to collimate light.
    Type: Application
    Filed: May 1, 2018
    Publication date: November 7, 2019
    Inventors: Stephan Lutgen, David Massoubre