Solid state bidirectional light sheet having vertical orientation

• US 8,414,154 B2
• Filed: 05/31/2012
• Issued: 04/09/2013
• Est. Priority Date: 11/01/2010
• Status: Active Grant

• Current Assignee: Quarkstar LLC
• Original Assignee: Quarkstar LLC
• Inventors: Dau, Wilson, Lerman, Louis, York, Allan Brent
• Primary Examiner(s): Negron, Ismael
• Application Number:
  US13/484,550
• Publication Number:
  US 20120250319A1
• Time in Patent Office: 313 Days
• Field of Search: 362/97.3, 362/147, 362/236, 362/240, 362/242, 362/244, 362/249.02, 362/249.06
• US Class Current: 362/249.02
• CPC Class Codes: F21K 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
• CPC Class Codes: F21S 8/04 intended only for mounting on a ceiling or the like overhead structures F21S8/02 takes precedence; details of ceiling bases F21V21/03
• CPC Class Codes: F21S 8/046 having multiple lighting devices, e.g. connected to a common ceiling base
• CPC Class Codes: F21S 8/06 by suspension
• CPC Class Codes: F21S 8/068 from a stretched wire
• CPC Class Codes: F21V 21/14 Adjustable mountings
• CPC Class Codes: F21V 21/16 using wires or cords
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 5/10 comprising photoluminescent material
• CPC Class Codes: F21V 7/00 Reflectors for light sources characterised by cooling arrangements F21V29/505
• CPC Class Codes: F21V 7/0016 on lighting devices that also provide for direct lighting, e.g. by means of independent light sources, by splitting of the light beam, by switching between both lighting modes
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2107/90 on two opposite sides of supports or substrates
• CPC Class Codes: F21Y 2109/00 Light sources with light-generating elements disposed on transparent or translucent supports or substrates
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 25/0756 Stacked arrangements of devices
• 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: H05K 1/189 : characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/10106 : Light emitting diode [LED]

Abstract

An array of LEDs (e.g., 500 LEDs) is sandwiched between at least two transparent substrates having conductors bonded to the electrodes without wires, forming light sheets to emit light from opposite surfaces of the light sheet to create a bidirectional light sheet. The light sheet may be suspended from a ceiling to be perpendicular to the ceiling, or the angles of the light sheet may be adjusted. The suspended light sheet may form a cylinder for uniform illumination of the floor and ceiling. Lenses may be formed in the light sheet.

Claims

1. A lighting device for general illumination comprising:

two or more bidirectional light sheets, each bidirectional light sheet being planar and comprising;

a first substrate comprising a first light emitting surface,

a second substrate comprising a second light emitting surface opposing the first light emitting surface,

a plurality of first non-packaged light emitting diode (LED) dies, and

a plurality of second non-packaged LED dies, the first and second non-packaged LED dies being disposed between the first and second substrates such that during operation of the lighting device a peak intensity of light emitted by the first non-packaged LED dies is output from the first light emitting surface in a first direction, and a peak intensity of light emitted by the second non-packaged LED dies is output from the second light emitting surface in a second direction different from the first direction,

a plurality of conductors configured to provide power to the first and second non-packaged LED dies, the first and second non-packaged LED dies connected to the conductors without wires, the conductors formed on at least one of the first and second substrate; and

a support for affixing the two or more planar bidirectional light sheets to a ceiling, the support comprising a planar base, wherein each of the two or more planar bidirectional light sheets has an edge affixed to the planar base, such that the first and second light emitting surfaces of at least one of the planar bidirectional light sheets are non-parallel to the ceiling, and an angle formed by each of the two or more planar bidirectional light sheets with respect to a surface normal of the planar base is individually adjustable.

2. The lighting device of claim 1, wherein

the first and second non-packaged LED dies are vertical dies and first ones of the conductors are formed on the first substrate and second ones of the conductors are formed on the second substrate.

3. The lighting device of claim 1, wherein

the first and second non-packaged LED dies are flip-chip dies and the conductors are formed on one of the first and second substrate.

4. The lighting device of claim 1, wherein

the first substrate comprises first refractive optical elements to direct, in the first direction relative to the first light emitting surface of the bidirectional light sheet, a peak intensity of the light emitted by the first non-packaged LED dies, and

the second substrate comprises second refractive optical elements to direct, in the second direction relative to the second light emitting surface of the bidirectional light sheet, another peak intensity of the light emitted by the second non-packaged LED dies.

5. The lighting device of claim 4, wherein the first and second refractive elements are lenses.

6. The lighting device of claim 1, wherein each of the two or more bidirectional sheets additionally comprises an intermediate layer.

7. The lighting device of claim 6, wherein the intermediate layer is a reflective layer.

8. The lighting device of claim 7, wherein the first non-packaged LED dies are located between the reflective layer and a light output surface of the first substrate, and the second non-packaged LED dies are located between the reflective layer and a light output surface of the second substrate.

9. A lighting device for general illumination comprising:

two or more bidirectional light sheets, each bidirectional light sheet comprising;

a sheet comprising a first sheet surface and a second sheet surface,

a first base substrate comprising a first indented surface and a first base surface opposing the first indented surface, wherein the first base surface is adjacent to the first sheet surface and the first indented surface comprises a plurality of first indentations, the first indentations being spaced apart from one another,

a second base substrate comprising a second indented surface and a second base surface opposing the second indented surface, wherein the second base surface is adjacent to the second sheet surface such that the sheet is sandwiched between the first and second base substrates, and the second indented surface comprises a plurality of second indentations, the second indentations being spaced apart from one another,

a first substrate comprising a first light emitting surface and a first cover surface, the first cover surface of the first substrate being in contact with the first indented surface of the first base substrate between the spaced apart first indentations,

a plurality of first non-packaged light emitting diode (LED) dies being disposed between the first base substrate and the first substrate in respective first indentations such that during operation of the bidirectional light sheet a peak intensity of light emitted by the first non-packaged LED dies is output from the first light emitting surface in a first direction,

a plurality of first conductors configured to provide power to the first non-packaged LED dies, where the first non-packaged LED dies are connected to the first conductors without wires, and the first conductors are formed on the first indented surface of the first base substrate and on the first cover surface of the first substrate,

a second substrate comprising a second light emitting surface and a second cover surface, the second cover surface of the second substrate being in contact with the second indented surface of the second base substrate between the spaced apart second indentations,

a plurality of second non-packaged light emitting diode (LED) dies being disposed between the second base substrate and the second substrate in respective second indentations such that during operation of the bidirectional light sheet a peak intensity of light emitted by the second non-packaged LED dies is output from the second light emitting surface in a second direction different from the first direction, and

a plurality of second conductors configured to provide power to the second non-packaged LED dies, where the second non-packaged LED dies are connected to the second conductors without wires, and the second conductors are formed on the second indented surface of the second base substrate and on the second cover surface of the second substrate; and

a support for affixing the two or more bidirectional light sheets to a ceiling such that the first and second light emitting surfaces of at least one of the bidirectional light sheets are non-parallel to the ceiling.

10. The lighting device of claim 9, wherein

the support comprises a planar base,

each of the two or more bidirectional light sheets is planar and has an edge affixed to the planar base.

11. The lighting device of claim 9, wherein the support comprises two or more wires to suspend the two or more bidirectional light sheets from the ceiling.

12. The lighting device of claim 9, wherein

the support comprises a base to be mounted against the ceiling, and

the two or more bidirectional light sheets are affixed to the base.

13. The lighting device of claim 9, wherein

the two or more bidirectional light sheets comprise two bidirectional light sheets joined along one edge, such that a line that is perpendicular to the one edge joining the two bidirectional light sheets is contained in each of the two bidirectional light sheets, and

the peak intensity of the light output from one of the two joined bidirectional light sheets is directed towards the ceiling and the peak intensity of the light output from the other one of the two joined bidirectional light sheets is directed towards a floor opposite the ceiling.

14. The lighting device of claim 13, wherein the one edge joining the two bidirectional light sheets is straight and the two bidirectional light sheets are coplanar.

15. The lighting device of claim 14, wherein the two joined, coplanar bidirectional light sheets are perpendicular to the ceiling.

16. The lighting device of claim 13, wherein the support affixes the two joined bidirectional light sheets to the ceiling, such that the one edge joining the two bidirectional light sheets is parallel to the ceiling.

17. The lighting device of claim 16, wherein the one edge joining the two bidirectional light sheets is curved and the two bidirectional light sheets form a shell perpendicular to the ceiling.

18. The lighting device of claim 17, wherein the one edge joining the two bidirectional light sheets is a circle and the two bidirectional light sheets form a cylindrical shell perpendicular to the ceiling.

19. A lighting device for general illumination comprising:

four bidirectional light sheets, each bidirectional light sheet being a planar trapezoid and comprising;

a first substrate comprising a first light emitting surface,

a second substrate comprising a second light emitting surface opposing the first light emitting surface,

a plurality of first non-packaged light emitting diode (LED) dies, and

a plurality of second non-packaged LED dies, the first and second non-packaged LED dies being disposed between the first and second substrates such that during operation of the lighting device a peak intensity of light emitted by the first non-packaged LED dies is output from the first light emitting surface in a first direction, and a peak intensity of light emitted by the second non-packaged LED dies is output from the second light emitting surface in a second direction different from the first direction,

a plurality of conductors configured to provide power to the first and second non-packaged LED dies, the first and second non-packaged LED dies connected to the conductors without wires, the conductors formed on at least one of the first and second substrate; and

a support for affixing the four planar bidirectional light sheets to a ceiling, the support comprising a planar base, wherein each of the four planar bidirectional light sheets has an edge affixed to the planar base and two edges joined with corresponding edges of two other of the four bidirectional light sheets, such that the four bidirectional light sheets form a truncated pyramid shell with two opposite openings, and

during operation,

the support affixes the truncated pyramid shell to the ceiling such that one of the two openings faces the ceiling and the other one faces a floor opposite the ceiling, and

the peak intensity of the light output from the inner surface of the truncated pyramid shell is directed towards the ceiling and the peak intensity of the light output from the outer surface of the truncated pyramid shell is directed towards the floor.

20. The lighting device of claim 19, wherein

the truncated pyramid shell comprises an additional bidirectional light sheet that is shaped like the one of the two openings of the truncated pyramid shell that faces the floor, and

edges of the additional bidirectional light sheet are joined with the edges of the one of the two openings of the truncated pyramid shell that faces the floor.

21. The lighting device of claim 19, wherein each of the two openings is shaped like a regular polygon.

22. A lighting device for general illumination comprising:

four bidirectional light sheets, each bidirectional light sheet being planar and comprising;

a first substrate comprising a first light emitting surface,

a second substrate comprising a second light emitting surface opposing the first light emitting surface,

a plurality of first non-packaged light emitting diode (LED) dies, and

a plurality of second non-packaged LED dies, the first and second non-packaged LED dies being disposed between the first and second substrates such that during operation of the lighting device a peak intensity of light emitted by the first non-packaged LED dies is output from the first light emitting surface in a first direction, and a peak intensity of light emitted by the second non-packaged LED dies is output from the second light emitting surface in a second direction different from the first direction,

a plurality of conductors configured to provide power to the first and second non-packaged LED dies, the first and second non-packaged LED dies connected to the conductors without wires, the conductors formed on at least one of the first and second substrate; and

a support for affixing the four planar bidirectional light sheets to a ceiling, the support comprising a planar base, such that each of the four planar bidirectional light sheets has an edge affixed to the planar base, wherein the four planar bidirectional light sheets are parallel to a surface normal of the planar base, and the affixed edges outline a rectangle.

23. A lighting device for general illumination comprising:

two or more bidirectional light sheets, each bidirectional light sheet being planar and comprising;

a first substrate comprising a first light emitting surface,

a second substrate comprising a second light emitting surface opposing the first light emitting surface,

a plurality of first non-packaged light emitting diode (LED) dies, and

a plurality of second non-packaged LED dies, the first and second non-packaged LED dies being disposed between the first and second substrates such that during operation of the lighting device a peak intensity of light emitted by the first non-packaged LED dies is output from the first light emitting surface in a first direction, and a peak intensity of light emitted by the second non-packaged LED dies is output from the second light emitting surface in a second direction different from the first direction,

a plurality of conductors configured to provide power to the first and second non-packaged LED dies, the first and second non-packaged LED dies connected to the conductors without wires, the conductors formed on at least one of the first and second substrate; and

a support for affixing the two or more planar bidirectional light sheets to a ceiling such that the first and second light emitting surfaces of at least one of the planar bidirectional light sheets are non-parallel to the ceiling, the support comprising a planar base, wherein each of the two or more planar bidirectional light sheets has an edge affixed to the planar base, and when the planar base of the support is affixed to the ceiling, peak intensities of the light output from the two or more planar bidirectional light sheets during operation are directed towards a floor opposite the ceiling.