Light emitting, photovoltaic or other electronic apparatus and system

• US 10,516,073 B2
• Filed: 12/08/2017
• Issued: 12/24/2019
• Est. Priority Date: 05/31/2007
• Status: Active Grant

• Current Assignee: NthDegree Technologies Worldwide Inc.
• Original Assignee: NthDegree Technologies Worldwide Inc.
• Inventors: Ray, William Johnstone, Lowenthal, Mark D., Shotton, Neil O., Blanchard, Richard A., Lewandowski, Mark Allan, Fuller, Kirk A., Frazier, Donald Odell
• Primary Examiner(s): Rodriguez, Armando
• Application Number:
  US15/835,944
• Publication Number:
  US 20180102457A1
• Time in Patent Office: 746 Days
• CPC Class Codes: B82Y 20/00 Nanooptics, e.g. quantum optics or photonic crystals
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: H01L 21/30 Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 manufacture of electrodes thereon H01L21/28
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 27/142 Energy conversion devices photovoltaic modules or arrays of single photovoltaic cells comprising bypass diodes integrated or directly associated with the devices H01L31/0443; photovoltaic modules composed of a plurality of thin film solar cells deposited on the same substrate H01L31/046
• CPC Class Codes: H01L 27/156 two-dimensional arrays
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01L 31/028 including, apart from doping material or other impurities, only elements of Group IV of the Periodic Table
• CPC Class Codes: H01L 31/0304 including, apart from doping materials or other impurities, only AIIIBV compounds
• CPC Class Codes: H01L 31/03044 comprising a nitride compounds, e.g. GaN
• CPC Class Codes: H01L 31/0328 including, apart from doping materials or other impurities, semiconductor materials provided for in two or more of groups H01L31/0272 - H01L31/032
• CPC Class Codes: H01L 31/0352 characterised by their shape or by the shapes, relative sizes or disposition of the semiconductor regions
• CPC Class Codes: H01L 31/035281 Shape of the body
• CPC Class Codes: H01L 31/0475 PV cell arrays made by cells in a planar, e.g. repetitive, configuration on a single semiconductor substrate; PV cell microarrays PV modules composed of a plurality of thin film solar cells deposited on the same substrate H01L31/046
• CPC Class Codes: H01L 31/05 Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells electrodes H01L31/0224; electrical interconnection of thin film solar cells formed on a common substrate H01L31/046; particular structures for electrical interconnecting of adjacent thin film solar cells in the module H01L31/0465; electrical interconnection means specially adapted for electrically connecting two or more PV modules H02S40/36
• CPC Class Codes: H01L 31/0504 specially adapted for series or parallel connection of solar cells in a module
• CPC Class Codes: H01L 31/0508 the interconnection means having a particular shape
• CPC Class Codes: H01L 31/0512 made of a particular material or composition of materials
• CPC Class Codes: H01L 31/0543 comprising light concentrating means of the refractive type, e.g. lenses
• CPC Class Codes: H01L 31/0547 : comprising light concentrating means of the reflecting type, e.g. parabolic mirrors, concentrators using total internal reflection
• CPC Class Codes: H01L 31/068 : the potential barriers being only of the PN homojunction type, e.g. bulk silicon PN homojunction solar cells or thin film polycrystalline silicon PN homojunction solar cells
• CPC Class Codes: H01L 33/00 : Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof H10K50/00 takes precedence; devices consisting of a plurality of semiconductor components formed in or on a common substrate and including semiconductor components having potential barriers, specially adapted for light emission H01L27/15; semiconductor lasers H01S5/00
• CPC Class Codes: H01L 33/08 : with a plurality of light emitting regions, e.g. laterally discontinuous light emitting layer or photoluminescent region integrated within the semiconductor body H01L27/15 takes precedence
• CPC Class Codes: H01L 33/20 : with a particular shape, e.g. curved or truncated substrate
• CPC Class Codes: H01L 33/30 : containing only elements of Group III and Group V of the Periodic Table
• CPC Class Codes: H01L 33/32 : containing nitrogen
• CPC Class Codes: H01L 33/34 : containing only elements of Group IV of the Periodic Table
• CPC Class Codes: H01L 33/58 : Optical field-shaping elements
• CPC Class Codes: H01L 33/60 : Reflective elements
• CPC Class Codes: H01L 33/62 : Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls
• CPC Class Codes: H10K 2102/331 : Nanoparticles used in non-emissive layers, e.g. in packaging layer
• CPC Class Codes: H10K 30/87 : Light-trapping means
• CPC Class Codes: H10K 50/80 : Constructional details
• CPC Class Codes: H10K 50/805 : Electrodes
• CPC Class Codes: H10K 50/852 : comprising a resonant cavity structure, e.g. Bragg reflector pair
• CPC Class Codes: H10K 50/856 : comprising reflective means
• CPC Class Codes: H10K 50/858 : comprising refractive means, e.g. lenses
• CPC Class Codes: H10K 59/00 : Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
• CPC Class Codes: H10K 59/17 : Passive-matrix OLED displays
• CPC Class Codes: H10K 71/00 : Manufacture or treatment specially adapted for the organic devices covered by this subclass
• CPC Class Codes: H10K 77/10 : Substrates, e.g. flexible substrates
• CPC Class Codes: Y02E 10/52 : PV systems with concentrators
• CPC Class Codes: Y02E 10/544 : Solar cells from Group III-V materials
• CPC Class Codes: Y02E 10/547 : Monocrystalline silicon PV cells
• CPC Class Codes: Y02E 10/549 : Organic PV cells
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

The present invention provides an electronic apparatus, such as a lighting device comprised of light emitting diodes (LEDs) or a power generating apparatus comprising photovoltaic diodes, which may be created through a printing process, using a semiconductor or other substrate particle ink or suspension and using a lens particle ink or suspension. An exemplary apparatus comprises a base; at least one first conductor; a plurality of diodes coupled to the at least one first conductor; at least one second conductor coupled to the plurality of diodes; and a plurality of lenses suspended in a polymer deposited or attached over the diodes. The lenses and the suspending polymer have different indices of refraction. In some embodiments, the lenses and diodes are substantially spherical, and have a ratio of mean diameters or lengths between about 10:1 and 2:1. The diodes may be LEDs or photovoltaic diodes, and in some embodiments, have a junction formed at least partially as a hemispherical shell or cap.

Claims

1. An apparatus, comprising:

at least one first conductor;

a plurality of diodes coupled to the at least one first conductor, each diode of the plurality of diodes comprising a diode substrate and having a surface, wherein fifteen percent to fifty-five percent of the surface of each diode of the plurality of diodes has a penetration layer or region extending into the diode substrate and having a first majority carrier or dopant, the remaining diode substrate having a second majority carrier or dopant;

at least one second conductor coupled to the plurality of diodes; and

at least one lens coupled over the plurality of diodes and any intervening layers.

2. The apparatus of claim 1, wherein the at least one lens further comprises a plurality of lenses having at least a first index of refraction, the plurality of lenses suspended in a first polymer having at least a second, different index of refraction.

3. The apparatus of claim 1, wherein the at least one first conductor further forms or comprises a base.

4. The apparatus of claim 1, wherein a mean size of the plurality of diodes is between ten microns and forty microns;

and wherein the at least one lens further comprises a plurality of spherical lenses, wherein the plurality of diodes are spherical, and wherein a ratio of a mean diameter of the plurality of spherical lenses to a mean diameter of the plurality of diodes is between ten to one (10;

1) and two to one (2;

1).

5. The apparatus of claim 1, wherein the plurality of diodes are selected from the group consisting of:

semiconductor light emitting diodes, organic light emitting diodes, polymer light emitting diodes, photovoltaic diodes, and combinations thereof.

6. The apparatus of claim 1, wherein the plurality of diodes comprise a material selected from the group consisting of:

gallium nitride, gallium arsenide, silicon, and combinations thereof.

7. The apparatus of claim 1, further comprising a base coupled to the at least one first conductor, the base having a reflector or a refractor.

8. The apparatus of claim 1, further comprising a base coupled to the at least one first conductor, the base comprising:

at least one conductive via extending between a first side and a second side of the base and coupled at the first side to the at least one first conductor; and

a conductive backplane coupled to the at least one conductive via and coupled to or integrated with the second side of the base.

9. The apparatus of claim 1, further comprising:

at least one insulator coupled to the plurality of diodes and comprising a plurality of inorganic dielectric particles suspended with a photoinitiator in a polymer or resin.

10. The apparatus of claim 1, further comprising a base coupled to the at least one first conductor, the base comprising a material selected from the group consisting of:

paper, coated paper, plastic coated paper, embossed paper, fiber paper, cardboard, poster paper, poster board, wood, plastic, rubber, fabric, glass, ceramic, and combinations thereof.

11. The apparatus of claim 1, wherein the at least one first conductor comprises a metal foil or a sputtered, coated, vapor deposited or electroplated metal, metal alloy, or combination of metals, and wherein the at least one second conductor comprises an optically transmissive polymer.

12. The apparatus of claim 1, wherein the plurality of diodes are annealed, or alloyed, or chemically coupled to or within the at least one first conductor.

13. The apparatus of claim 1, further comprising:

an electrical or electronic interface coupled electrically to the at least one first conductor and to the at least one second conductor.

14. The apparatus of claim 1, wherein the plurality of diodes are selected from the group consisting of:

spherical, toroidal, cylindrical, faceted, rectangular, flat, elliptical, and combinations thereof.

15. A system, comprising:

an electrical or electronic interface;

a base coupled to the electrical or electronic interface;

at least one first conductor coupled to or forming the base and electrically coupled to the electrical or electronic interface;

a plurality of diodes coupled to the at least one first conductor, each diode of the plurality of diodes comprising a diode substrate and having a surface, wherein fifteen percent to fifty-five percent of the surface of each diode of the plurality of diodes has a penetration layer or region extending into the diode substrate and having a first majority carrier or dopant, the remaining diode substrate having a second majority carrier or dopant;

at least one second conductor coupled to the plurality of diodes; and

at least one lens coupled over the plurality of diodes and any intervening layers.

16. The system of claim 15, wherein the at least one lens comprises a plurality of lenses and wherein the plurality of lenses are sized and spaced relative to the plurality of diodes to the provide a mode coupling to the plurality of diodes.

17. The system of claim 15, wherein the at least one lens comprises:

a plurality of lenses suspended in a first polymer and coupled to the plurality of diodes, the plurality of lenses having at least a first index of refraction and the first polymer having at least a second, different index of refraction.

18. The system of claim 15, wherein the at least one first conductor comprises a metal foil or a sputtered, coated, vapor deposited or electroplated metal, metal alloy, or combination of metals;

wherein the at least one second conductor comprises an optically transmissive polymer; and

wherein the plurality of diodes are annealed, or alloyed, or chemically coupled to or within the at least one first conductor.

19. The system of claim 15, wherein the base further comprises a reflector or a refractor.

20. A system, comprising:

an electrical or electronic interface;

at least one first conductor coupled electrically to the electrical or electronic interface;

a plurality of diodes coupled to the at least one first conductor, each diode of the plurality of diodes comprising a diode substrate and having a surface, wherein fifteen percent to fifty-five percent of the surface of each diode of the plurality of diodes has a penetration layer or region extending into the diode substrate and having a first majority carrier or dopant, the remaining diode substrate having a second majority carrier or dopant, wherein a mean size of the plurality of diodes is between ten microns and forty microns;

at least one second conductor coupled to the plurality of diodes; and

a plurality of lenses coupled over the plurality of diodes and any intervening layers, the plurality of lenses comparatively sized to the plurality of diodes and spaced apart from the plurality of diodes to the provide a resonant mode coupling to the plurality of diodes.