Method of manufacturing a light emitting, photovoltaic or other electronic apparatus and system
The present invention provides a method of manufacturing an electronic apparatus, such as a lighting device having light emitting diodes (LEDs) or a power generating device having photovoltaic diodes. The exemplary method includes depositing a first conductive medium within a plurality of channels of a base to form a plurality of first conductors; depositing within the plurality of channels a plurality of semiconductor substrate particles suspended in a carrier medium; forming an ohmic contact between each semiconductor substrate particle and a first conductor; converting the semiconductor substrate particles into a plurality of semiconductor diodes; depositing a second conductive medium to form a plurality of second conductors coupled to the plurality of semiconductor diodes; and depositing or attaching a plurality of lenses suspended in a first polymer over the plurality of diodes. In various embodiments, the depositing, forming, coupling and converting steps are performed by or through a printing process.
1. A method of manufacturing an electronic apparatus, the method comprising:
depositing a first conductive medium within a plurality of channels of a base to form a plurality of first conductors;
depositing within the plurality of channels a plurality of semiconductor substrate particles suspended in a carrier medium;
forming an ohmic contact between each semiconductor substrate particle of the plurality of semiconductor substrate particles and a first conductor of the plurality of first conductors;
converting the plurality of semiconductor substrate particles into a plurality of semiconductor diodes, wherein about fifteen percent to fifty-five percent of a surface of each diode of substantially all of the plurality of diodes has a penetration layer or region having a first majority carrier or dopant and the remaining diode substrate has a second majority carrier or dopant;
depositing a second conductive medium to form a plurality of second conductors coupled to the plurality of semiconductor diodes; and
depositing a plurality of lenses.
2. The method of claim 1 , wherein the plurality of semiconductor diodes have shapes selected from the group consisting of: substantially spherical, substantially toroidal, substantially cylindrical, substantially faceted, substantially rectangular, substantially flat, substantially elliptical, and mixtures or combinations thereof.
3. The method of claim 1 , wherein the plurality of lenses have shapes selected from the group consisting of: substantially spherical, substantially hemispherical, substantially faceted, substantially elliptical, substantially oblong, substantially cubic, substantially prismatic, substantially trapezoidal, substantially triangular, substantially pyramidal, and mixtures or combinations thereof.
4. The method of claim 1 , wherein the plurality of semiconductor diodes and the plurality of lenses are substantially spherical, and wherein a ratio of a mean diameter of the plurality of lenses to a mean diameter of the plurality of semiconductor diodes is substantially about five to one (5:1).
5. The method of claim 1 , wherein the plurality of semiconductor diodes and the plurality of lenses are substantially spherical, and wherein a ratio of a mean diameter of the plurality of lenses to a mean diameter of the plurality of semiconductor diodes is between about ten to one (10:1) and two to one (2:1).
6. The method of claim 1 , wherein the plurality of semiconductor diodes and the plurality of lenses are substantially spherical, and wherein the comparative size or spacing of the plurality of substantially spherical lenses provide a mode coupling to the plurality of diodes.
7. The method of claim 1 , wherein a mean diameter or length of the plurality of semiconductor diodes is greater than about twenty (20) microns and less than about forty (40) microns.
8. The method of claim 1 , wherein the step of depositing the plurality of lenses further comprises attaching a prefabricated lens layer to the plurality of semiconductor diodes, the prefabricated lens layer comprising the plurality of lenses.
9. The method of claim 1 , wherein the plurality of semiconductor substrate particles comprise at least one semiconductor selected from the group consisting of: gallium nitride, gallium arsenide, silicon, and combinations thereof.
10. The method of claim 1 , further comprising:
partially curing the first conductive medium;
wherein the step of forming an ohmic contact further comprises fully curing the first conductive medium.
11. The method of claim 10 , wherein the first conductive medium comprises a conductive ink or a conductive polymer.
12. The method of claim 1 , wherein the step of depositing the first conductive medium comprises at least one deposition process selected from the group consisting of: sputtering, coating, vapor depositing, electroplating, and combinations thereof; and wherein the first conductive medium is at least one conductive medium selected from the group consisting of: a metal, a metal alloy, and combinations thereof.
13. The method of claim 1 , wherein the carrier medium is a reactive carrier medium and wherein the step of forming an ohmic contact further comprises:
removing the reactive carrier medium; and
curing or re-curing the first conductive medium.
14. The method of claim 1 , wherein the carrier medium is an anisotropic carrier medium and wherein the step of forming an ohmic contact further comprises:
compressing the plurality of semiconductor substrate particles suspended in the anisotropic conductive medium.
15. The method of claim 1 , wherein the step of forming an ohmic contact further comprises:
annealing or alloying the plurality of semiconductor substrate particles within the plurality of channels.
16. The method of claim 1 , wherein the plurality of channels are spaced-apart and substantially parallel.
17. The method of claim 1 , wherein the plurality of channels are at least partially hemispherically-shaped and are disposed in an array.
18. The method of claim 1 , wherein the plurality of channels are spaced-apart and least partially parabolic.
19. The method of claim 1 , wherein the base further comprises a plurality of angled ridges.
20. The method of claim 1 , wherein the plurality of spaced-apart channels further comprise a plurality of integrally formed projections or supports.
21. The method of claim 20 , wherein the plurality of first conductors are coupled to the plurality of integrally formed projections or supports within the plurality of spaced-apart channels and wherein the step of forming an ohmic contact further comprises:
annealing, or alloying, or chemically coupling the plurality of substrate particles to the plurality of first conductors.
22. The method of claim 1 , wherein the step of converting the plurality of semiconductor substrate particles into the plurality of semiconductor diodes further comprises:
forming a pn junction in each semiconductor substrate particle by depositing a dopant material onto the plurality of semiconductor substrate particles and annealing or alloying the dopant material with the plurality of substrate particles.
23. The method of claim 22 , wherein the annealing or alloying is laser or thermal annealing or alloying.
24. The method of claim 22 , wherein the dopant material is a substrate liquid or film or a dopant element or compound suspended in a carrier.
25. The method of claim 22 , wherein the pn junction is formed at least a partially hemispherical shell or cap.
26. The method of claim 22 , wherein the dopant material is deposited on a first, upper portion of the plurality of substrate particles to form the plurality of diodes.
27. The method of claim 22 , wherein the resulting plurality of diodes are light emitting diodes or photovoltaic diodes.
28. The method of claim 1 , further comprising:
depositing a plurality of third conductors over or within the plurality of second conductors.
29. The method of claim 1 , wherein the base further comprises a Bragg reflector or a reflective plastic or polyester coating.
30. The method of claim 1 , wherein the base further comprises:
a plurality of conductive vias extending between a first side and a second side of the base and correspondingly coupled at the first side to the plurality of first conductors; and
a conductive backplane coupled to the plurality of conductive vias and coupled to or integrated with the second side of the base.
31. The method of claim 1 , further comprising:
depositing a plurality of inorganic dielectric particles suspended with a photoinitiator compound in a polymer or resin to form a plurality of insulators correspondingly coupled to each of the plurality of diodes.
32. The method of claim 1 , wherein the base comprises at least one 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.
33. The method of claim 1 , wherein the step of depositing a second conductive medium further comprises:
depositing an optically transmissive conductor or conductive compound suspended in a polymer, resin or other media.
34. The method of claim 33 , wherein the optically transmissive conductor or conductive compound suspended in a polymer, resin or other media further comprises at least one of the following: carbon nanotubes, antimony tin oxide, indium tin oxide, or polyethylene-dioxithiophene.
35. The method of claim 1 , wherein the depositing and converting steps are performed by or through a printing process.
36. The method of claim 1 , wherein the plurality of lenses comprise borosilicate glass or polystyrene latex.
37. The method of claim 1 , further comprising:
attaching an interface for insertion into a standardized lighting socket.
38. The method of claim 37 , wherein the interface is compatible with an E12, E14, E26, E27, or GU-10 lighting standard.
39. The method of claim 37 , wherein the interface is compatible with a standard Edison-type lighting socket.
40. The method of claim 37 , wherein the interface is compatible with a standard fluorescent-type lighting socket.
41. The method of claim 1 , wherein the plurality of lenses have at least a first index of refraction and are suspended in a polymer, wherein the polymer has at least a second, different index of refraction.
42. The method of claim 1 , wherein the deposition steps further comprise at least one deposition process selected from the group consisting of: printing, coating, rolling, spraying, layering, sputtering, lamination, screen printing, inkjet printing, electro-optical printing, electroink printing, photoresist printing, thermal printing, laser jet printing, magnetic printing, pad printing, flexographic printing, hybrid offset lithography, Gravure printing, and combinations thereof.
43. The method of claim 1 , wherein the step of depositing the first conductive medium further comprises coating the plurality of channels with the first conductive medium and removing excess first conductive medium by scraping a first surface of the base using a doctor blade.
44. The method of claim 1 , wherein the step of depositing the plurality of semiconductor substrate particles further comprises coating the plurality of channels with the plurality of semiconductor substrate particles suspended in a carrier medium and removing excess plurality of spherical substrate particles by scraping a first surface of the base using a doctor blade.
45. A method of manufacturing an electronic apparatus, the method comprising:
depositing a first conductive medium on a base to form at least one first conductor;
depositing a plurality of semiconductor substrate particles suspended in a liquid or gel carrier medium, wherein the plurality of semiconductor substrate particles are inorganic and substantially spherical;
forming one or more ohmic contacts between at least some semiconductor substrate particles of the plurality of semiconductor substrate particles and the at least one first conductor;
converting at least some semiconductor substrate particles of the plurality of semiconductor substrate particles into a plurality of semiconductor diodes, wherein the plurality of semiconductor diodes are substantially spherical and wherein about fifteen percent to fifty-five percent of a surface of each semiconductor diode of substantially all of the plurality of semiconductor diodes has a penetration layer or region having a first majority carrier or dopant and the remaining diode substrate has a second majority carrier or dopant;
depositing a second conductive medium to form a plurality of second conductors coupled to the plurality of semiconductor diodes; and
depositing a plurality of lenses suspended in a first polymer over the plurality of semiconductor diodes, wherein the plurality of lenses are substantially spherical and have at least a first index of refraction and wherein the first polymer, when solidified or cured, has at least a second, different index of refraction.
46. A method of manufacturing an electronic apparatus, the method comprising:
depositing a first conductive medium on a base to form at least one first conductor;
depositing a plurality of semiconductor substrate particles suspended in a liquid or gel carrier medium, wherein the plurality of semiconductor substrate particles are inorganic and substantially spherical;
forming one or more ohmic contacts between at least some semiconductor substrate particles of the plurality of semiconductor substrate particles and the at least one first conductor;
depositing a dopant material onto the plurality of semiconductor substrate particles;
converting at least some semiconductor substrate particles of the plurality of semiconductor substrate particles into a plurality of semiconductor diodes, wherein the plurality of semiconductor diodes are substantially spherical and wherein about fifteen percent to fifty-five percent of a surface of each semiconductor diode of substantially all of the plurality of semiconductor diodes has a penetration layer or region having a first majority carrier or dopant and the remaining diode substrate has a second majority carrier or dopant;
depositing a second conductive medium to form a plurality of second conductors coupled to the plurality of semiconductor diodes, wherein the second conductive medium is substantially optically transmissive when solidified or cured; and
depositing a plurality of lenses suspended in a first polymer over the plurality of semiconductor diodes, wherein the plurality of lenses are substantially spherical and have at least a first index of refraction and wherein the first polymer, when solidified or cured, has at least a second, different index of refraction.