LED lighting apparatus formed by a printable composition of a liquid or gel suspension of diodes and methods of using same

• US 9,200,758 B2
• Filed: 04/14/2015
• Issued: 12/01/2015
• Est. Priority Date: 05/31/2007
• Status: Active Grant

• Current Assignee: NthDegree Technologies Worldwide Inc.
• Original Assignee: NthDegree Technologies Worldwide Inc.
• Inventors: Lowenthal, Mark David, Ray, William Johnstone, Shotton, Neil O., Blanchard, Richard A., Oraw, Brad, Lewandowski, Mark Allan, Baldridge, Jeffrey, Perozziello, Eric Anthony
• Primary Examiner(s): BRUCE, DAVID VERNON
• Application Number:
  US14/686,444
• Publication Number:
  US 20150219284A1
• Time in Patent Office: 231 Days
• Field of Search: 362/84
• US Class Current: 1/1
• CPC Class Codes: F21K 9/23 Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
• CPC Class Codes: F21K 9/232 specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
• CPC Class Codes: F21K 9/27 Retrofit light sources for lighting devices with two fittings for each light source, e.g. for substitution of fluorescent tubes
• 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: F21K 9/64 using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
• CPC Class Codes: F21V 19/0005 of sources having contact pins, wires or blades, e.g. pinch sealed lamp F21V19/001 takes precedence
• CPC Class Codes: F21V 23/04 the elements being switches safety devices F21V25/00
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 3/049 Patterns or structured surfaces for diffusing light, e.g. frosted surfaces
• CPC Class Codes: F21V 3/06 characterised by the material
• CPC Class Codes: F21V 5/048 the lens being a simple lens adapted to cooperate with a point-like source for emitting mainly in one direction and having an axis coincident with the main light transmission direction, e.g. convergent or divergent lenses, plano-concave or plano-convex lenses
• CPC Class Codes: F21V 7/0066 specially adapted to cooperate with point like light sources; specially adapted to cooperate with light sources the shape of which is unspecified F21V7/16 - F21V7/30 take precedence
• CPC Class Codes: F21V 9/30 Elements containing photoluminescent material distinct from or spaced from the light source shades F21V1/17; globes, bowls or cover glasses F21V3/08, F21V3/12; refractors F21V5/10; reflectors F21V7/26, F21V7/30; elements with provision for controlling the spectral properties or intensity F21V9/40
• CPC Class Codes: F21Y 2101/00 Point-like light sources
• CPC Class Codes: F21Y 2107/20 on convex supports or substrates, e.g. on the outer surface of spheres
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/24137 the bodies being arranged next to each other, e.g. on a common substrate
• CPC Class Codes: H01L 2224/32225 the item being non-metallic, e.g. insulating substrate with or without metallisation
• CPC Class Codes: H01L 2224/73267 Layer and HDI connectors
• CPC Class Codes: H01L 2224/95101 in a liquid medium
• CPC Class Codes: H01L 24/24 : of an individual high density interconnect connector
• CPC Class Codes: H01L 24/95 : at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips
• CPC Class Codes: H01L 25/0753 : the devices being arranged next to each other
• CPC Class Codes: H01L 27/153 : in a repetitive configuration, e.g. LED bars
• 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 2924/00014 : the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/0002 : Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01L 2924/09701 : Low temperature co-fired ceramic [LTCC]
• CPC Class Codes: H01L 2924/12041 : LED
• CPC Class Codes: H01L 2924/12042 : LASER
• CPC Class Codes: H01L 2924/13033 : TRIAC - Triode for Alternating Current - A bidirectional switching device containing two thyristor structures with common gate contact
• CPC Class Codes: H01L 2924/13034 : Silicon Controlled Rectifier [SCR]
• CPC Class Codes: H01L 2924/1305 : Bipolar Junction Transistor [BJT]
• CPC Class Codes: H01L 2924/1306 : Field-effect transistor [FET]
• CPC Class Codes: H01L 2924/13062 : Junction field-effect transistor [JFET]
• CPC Class Codes: H01L 2924/13091 : Metal-Oxide-Semiconductor Field-Effect Transistor [MOSFET]
• CPC Class Codes: H01L 2924/14 : Integrated circuits
• CPC Class Codes: H01L 33/06 : within the light emitting region, e.g. quantum confinement structure or tunnel barrier
• CPC Class Codes: H01L 33/20 : with a particular shape, e.g. curved or truncated substrate
• CPC Class Codes: H01L 33/22 : Roughened surfaces, e.g. at the interface between epitaxial layers
• CPC Class Codes: H01L 33/24 : of the light emitting region, e.g. non-planar junction
• CPC Class Codes: H01L 33/32 : containing nitrogen
• CPC Class Codes: H01L 33/38 : with a particular shape
• CPC Class Codes: H01L 33/382 : the electrode extending partially in or entirely through the semiconductor body
• CPC Class Codes: H01L 33/42 : Transparent materials
• CPC Class Codes: H01L 33/483 : Containers
• CPC Class Codes: H01L 33/486 : adapted for surface mounting
• CPC Class Codes: H01L 33/50 : Wavelength conversion elements
• CPC Class Codes: H01L 33/58 : Optical field-shaping 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 50/80 : Constructional details
• CPC Class Codes: H10K 50/805 : Electrodes
• CPC Class Codes: H10K 59/90 : Assemblies of multiple devices comprising at least one organic light-emitting element
• CPC Class Codes: H10K 71/00 : Manufacture or treatment specially adapted for the organic devices covered by this subclass

Abstract

An exemplary printable composition of a liquid or gel suspension of diodes comprises a plurality of diodes, a first solvent and/or a viscosity modifier. An exemplary apparatus comprises: a plurality of diodes; at least a trace amount of a first solvent; and a polymeric or resin film at least partially surrounding each diode of the plurality of diodes. Various exemplary diodes have a lateral dimension between about 10 to 50 microns and about 5 to 25 microns in height. Other embodiments may also include a plurality of substantially chemically inert particles having a range of sizes between about 10 to about 50 microns.

Claims

1. A lighting apparatus comprising:

a tubular housing;

at least one electrical interface coupled to at least one end of the tubular housing, the at least one electrical interface comprising at least one end cap having one or more pins extending therefrom; and

an illuminating element disposed within the tubular housing, the illuminating element formed from a composition comprising;

a first solvent;

a viscosity modifier; and

a plurality of light emitting diodes having a width less than or equal to 50 microns, each light emitting diode of the plurality of light emitting diodes comprising;

a light emitting region, the light emitting or absorbing region having a mesa region;

at least one first terminal coupled to the light emitting region; and

at least one second terminal coupled to the light emitting region.

2. The lighting apparatus of claim 1, wherein the tubular housing is transparent or translucent.

3. The lighting apparatus of claim 1, wherein the tubular housing is or further comprises a light diffusion or dispersion structure.

4. The lighting apparatus of claim 1, wherein the tubular housing has a form factor selected from the group consisting of:

cylindrical, spiral, conical, frustroconical, bulbous, elongated, flat, curled, and combinations thereof.

5. The lighting apparatus of claim 1, wherein the tubular housing comprises at least one material selected from the group consisting of:

metal, glass, plastic, polymer, polymeric, and combinations thereof.

6. The lighting apparatus of claim 1, wherein the tubular housing is rigid or flexible.

7. The lighting apparatus of claim 1, wherein the tubular housing further comprises a phosphor coating.

8. The lighting apparatus of claim 1, wherein the tubular housing, or the illuminating element, or both the tubular housing and the illuminating element, are substantially cylindrical.

9. The lighting apparatus of claim 1, wherein the lighting apparatus has a form factor compatible with insertion of the lighting apparatus into a standard fluorescent tube-type socket.

10. The lighting apparatus of claim 1, wherein the lighting apparatus has a form factor compatible or interchangeable with a T-type fluorescent tube.

11. The lighting apparatus of claim 1, wherein the lighting apparatus has a form factor compatible with a lighting standard.

12. The lighting apparatus of claim 1, wherein the lighting apparatus has a form factor compatible with a lighting standard selected from the group consisting of:

ES, E12, E14, E26, E27, SES, bi-pin, quad-pin, L1, PL-2 pin, PL-4 pin, G9 halogen capsule, G4 halogen capsule, GU10, GU5.3, bayonet, small bayonet.

13. The lighting apparatus of claim 1, wherein each diode of the plurality of light emitting diodes has a width between about 20 to 30 microns and a height between about 5 to 15 microns.

14. The lighting apparatus of claim 1, wherein each diode of the plurality of light emitting diodes further comprises at least one via structure coupling the first terminal or the second terminal to the light emitting or absorbing region.

15. The lighting apparatus of claim 14, wherein the via structure has a height from 7 microns to 9 microns and a width from 3 microns to 5 microns.

16. The lighting apparatus of claim 1, wherein each diode of the plurality of light emitting diodes has at least one lateral side having a height from 5 microns to 15 microns.

17. A method of using the lighting apparatus of claim 1, comprising inserting the lighting apparatus into a fluorescent tube-type socket.

18. A method comprising:

an individual using a lighting apparatus, the lighting apparatus comprising a tube or cylinder, an illuminating element disposed within the tube or cylinder, at least one end cap coupled to at least one end of the tube or cylinder, the at least one end cap comprising one or more pins extending therefrom; and

wherein the illuminating element comprises;

a first solvent;

a viscosity modifier; and

a plurality of light emitting diodes having a width less than 50 microns, each light emitting diode of the plurality of light emitting diodes comprising;

a light emitting or absorbing region having a mesa, a first terminal coupled to the light emitting or absorbing region; and

a second terminal coupled to the light emitting or absorbing region.

19. The method of claim 18, wherein each of the plurality of light emitting diodes has a width from about 20 microns to about 30 microns.

20. The method of claim 18, wherein each of the plurality of light emitting diodes has a height from about 10 microns to about 15 microns.

21. The method of claim 18, wherein the second terminal is coupled to the light emitting or absorbing region by a via structure.

22. The method of claim 21, wherein the via structure has a height from 7 about microns to about 9 microns.

23. The method of claim 21, wherein the via structure has a height from 7 about microns to about 9 microns and a width from 3 microns to 5 microns.

24. The method of claim 18, wherein each of the plurality of light emitting diodes has a lateral side having a height from about 5 microns to about 15 microns.

25. The method of claim 18, wherein the light emitting or absorbing region comprises an n+ GaN layer, a quantum well region, and a p+ GaN layer.

26. The method of claim 18, wherein each of the plurality of light emitting diodes has a width from about 15 microns to about 40 microns.

27. The method of claim 18, wherein the tube or cylinder is rigid.

28. The method of claim 18, wherein the illuminating element is substantially cylindrical.

29. The method of claim 18, wherein the step of using comprises inserting the lighting apparatus into a fluorescent tube-type socket.

30. A method comprising:

an individual using a lighting apparatus, the lighting apparatus comprising a tube or cylinder, an illuminating element disposed within the tube or cylinder, at least one end cap coupled to at least one end of the tube or cylinder, the at least one end cap comprising one or more pins extending therefrom; and

wherein the illuminating element comprises;

at least a trace amount of a first solvent;

a cured or polymerized viscosity modifier; and

a plurality of light emitting diodes having a width less than 50 microns, each light emitting diode of the plurality of light emitting diodes comprising;

a light emitting or absorbing region having a mesa, a first terminal coupled to the light emitting or absorbing region; and

a second terminal coupled to the light emitting or absorbing region.