A method for manufacturing a light-emitting panel sandwiches a plurality of micro-components
between two flexible substrates in a web configuration. Each micro-component contains
a gas or gas-mixture capable of ionization when a sufficiently large voltage is
supplied across the micro-component via at least two electrodes. The micro-components
are disposed in sockets formed at pre-determined locations in a first dielectric
substrate so that they are adjacent to electrodes imprinted in the first substrate.
Dielectric layers and the conductors for acting as electrodes are formed using
liquid processes or combined liquid and sheet processes, where liquid materials
are applied to the surface of the underlying layer, then cured to complete the
formation of layers. The assembled layers are coated with a protective coating
and may include an RF shield. In one embodiment, patterning of the conductors is
achieved by applying conductive ink using an ink jet process. In another embodiment,
the conductors may be patterned photolithographically using a leaky optical waveguide
as a contact mask.