Failure mitigation in arrays of light-emitting devices
View Patent ↗In accordance with certain embodiments, an illumination system comprising a plurality of power strings features elements facilitating compensation for failure of one or more light-emitting elements connected along each power string.
1. An illumination system comprising:
a plurality of power strings connectable to a power source, each power string comprising:
a power conductor;
along each power conductor, a plurality of contact pairs interrupting and spaced apart along the power conductor, the contacts within a pair being insulatively spaced apart and electrically bridged by a light-emitting element so that the light-emitting elements are connected along the power conductor; and
at a first contact pair, an element facilitating compensation for failure of the associated light-emitting element, the element comprising (i) a submount, (ii) a replacement light-emitting element disposed on the submount, and (iii) submount contacts extending from the submount and configured to electrically connect the replacement light-emitting element to the first contact pair.
2. The system of claim 1 , wherein the submount contacts penetrate at least a portion of the contact pair.
3. The system of claim 1 , wherein the submount contacts penetrate at least a portion of the power conductor.
4. The system of claim 1 , further comprising a substrate on which the first contact pair is disposed, wherein the submount contacts penetrate at least a portion of the substrate.
5. The system of claim 1 , wherein the replacement light-emitting element is disposed above at least a portion of the light-emitting element associated with the first contact pair.
6. The system of claim 1 , wherein at least one light-emitting element comprises a light-emitting diode.
7. The system of claim 1 , wherein at least one light-emitting element comprises an unpackaged light-emitting diode.
8. The system of claim 1 , wherein, in each power string, the light-emitting elements are electrically connected in series along the power conductor.
9. The system of claim 1 , wherein at least one light-emitting element comprises a phosphorescent material for converting at least a portion of light emitted by the light-emitting element from one set of wavelengths to another.
10. The system of claim 1 , wherein at least one light-emitting element is at least one of mechanically or electrically connected to the contacts of a contact pair by an adhesive.
11. The system of claim 10 , wherein the adhesive comprises a conductive adhesive.
12. The system of claim 11 , wherein the adhesive comprises an anisotropically conductive adhesive.
13. The system of claim 1 , wherein at least one light-emitting element is at least one of mechanically or electrically connected to the contacts of a contact pair by solder.
14. The system of claim 1 , further comprising a flexible substrate on which the plurality of power strings is disposed.
15. A method for repairing an illumination system comprising (a) a plurality of power strings connectable to a power source, each power string comprising (i) a power conductor, and (ii) along each power conductor, a plurality of contact pairs interrupting and spaced apart along the power conductor, the contacts within a pair being insulatively spaced apart and electrically bridged by a light-emitting element so that the light-emitting elements are connected along the power conductor, and (b) a failed light-emitting element associated with a first contact pair, the method comprising:
disposing at the first contact pair a submount having a replacement light-emitting element thereon; and
electrically connecting the replacement light-emitting element to the first contact pair.
16. The method of claim 15 , wherein the replacement light-emitting element is disposed over at least a portion of the failed light-emitting element.
17. The method of claim 15 , wherein (i) the submount comprises submount contacts electrically connected to the replacement light-emitting element, and (ii) electrically connecting the replacement light-emitting element to the first contact pair comprises penetrating, with the submount contacts, at least a portion of at least one of the first contact pair, the power conductor, or a substrate on which the first contact pair is disposed.
18. An illumination system comprising:
a power source;
a plurality of power strings connected to the power source, each power string comprising:
a power conductor, and
along each power conductor, a plurality of contact pairs interrupting and spaced apart along the power conductor, the contacts within a pair being insulatively spaced apart and electrically bridged by a light-emitting element so that the light-emitting elements are connected along the power conductor;
one or more reserve power strings selectively connectable to the power source, each reserve power string comprising:
a power conductor, and
along each power conductor, a plurality of contact pairs interrupting and spaced apart along the power conductor, the contacts within a pair being insulatively spaced apart and electrically bridged by a light-emitting element so that the light-emitting elements are connected along the power conductor; and
a controller for detecting failure of a power string and, thereafter, activating a reserve power string by connecting the reserve power string to the power source.
19. The system of claim 18 , wherein the controller is configured to activate a reserve power string proximate the failed power string.
20. The system of claim 18 , wherein, when connected to the power source, the one or more reserve power strings are connected in parallel with the plurality of power strings.