Abstract: An LED module is disclosed containing an integrated driver transistor (e.g, a MOSFET) in series with an LED. In one embodiment, LED layers are grown over a substrate. The transistor regions are formed over the same substrate. After the LED layers, such as GaN layers, are grown to form the LED portion, a central area of the LED is etched away to expose a semiconductor surface in which the transistor regions are formed. A conductor connects the transistor in series with the LED. Another node of the transistor is electrically coupled to an electrode on the bottom surface of the substrate. In one embodiment, an anode of the LED is connected to one terminal of the module, one current carrying node of the transistor is connected to a second terminal of the module, and the control terminal of the transistor is connected to a third terminal of the module.

Abstract: A layer of microscopic printed VLEDs is sandwiched between a first conductor layer and a transparent second conductor layer so that light exits the second conductor layer. Touch sensor electrodes are formed overlying the VLED layer so that the VLEDs illuminate the touch sensor. In one embodiment, the touch sensor electrodes are independent from the conductor layers for the VLEDs. In another embodiment, the transparent second conductor layer also serves as a touch sensor electrode. In another embodiment, both the conductor layers for the VLEDs serve as touch sensor electrodes. The conductor layers for the VLEDs may be segmented in groups to selectively illuminate groups of the VLEDs under each touch sensor position. The touch sensor electrodes may be transparent or opaque, depending on whether the electrodes are intended to allow the VLED light to pass through.

Abstract: A first layer of inorganic first vertical LED dies (VLEDs) of a first color is printed on a conductor surface. A first transparent conductor layer is deposited over the first VLEDs to electrically contact top electrodes of the first VLEDs. An electrically insulated second layer of second VLEDs of a second color is printed over the first transparent conductor layer, and an electrically insulated third layer of third VLEDs of a third color is printed over the first transparent conductor layer. For a color display, the VLEDs are printed in an addressable pixel array. Since the VLEDs are printed as an ink, the overlying VLEDs in a pixel are not vertically aligned, so there is little blockage of light. If the structure is used for general illumination, the VLEDs do not need to be printed in pixel areas.

Abstract: An LED module is disclosed containing an integrated driver transistor (e.g, a MOSFET) in series with an LED. In one embodiment, LED layers are grown over a substrate. The transistor regions are formed over the same substrate. After the LED layers, such as GaN layers, are grown to form the LED portion, a central area of the LED is etched away to expose a semiconductor surface in which the transistor regions are formed. A conductor connects the transistor in series with the LED. Another node of the transistor is electrically coupled to an electrode on the bottom surface of the substrate. In one embodiment, an anode of the LED is connected to one terminal of the module, one current carrying node of the transistor is connected to a second terminal of the module, and the control terminal of the transistor is connected to a third terminal of the module.

Abstract: A system of interconnectable LED light emitting tiles includes identical tiles having a light emitting area that extends all the way to two contiguous edges. One set of anode and cathode interconnects is accessible from the underside of one edge of the tile, and a second set of anode and cathode interconnects is accessible from the top side of an opposite edge of the tile. The second set of anode and cathode interconnects extends out from the light emitting area on the top side. When tiles are interconnected together, their interconnection edges overlap to make the electrical interconnections, while the light emitting areas of all the tiles abut to form a large seamless light emitting area. The flexible tiles may be mounted on a backplane that includes anode and cathode conductors for electrically interconnecting the tiles. A large, addressable display may be formed using interconnected tiles.

Abstract: A first layer of first vertical light emitting diodes (VLEDs) is printed on a conductor surface. A first transparent conductor layer is deposited over the first VLEDs to electrically contact top electrodes of the first VLEDs. A second layer of second VLEDs is printed on the first transparent conductor layer. Since the VLEDs are printed as an ink, the second VLEDs are not vertically aligned with the first VLEDs, so light from the first VLEDs is not substantially blocked by the second VLEDs when the VLEDs are turned on. A second transparent conductor layer is deposited over the second VLEDs to electrically contact top electrodes of the second VLEDs. By this structure, the first VLEDs are connected in parallel, the second VLEDs are connected in parallel, and the first layer of first VLEDs and the second layer of second VLEDs are connected in series by the first transparent conductor layer.

Abstract: Relatively small, electrically isolated segments of LED light sheets are fabricated having an anode terminal and a cathode terminal. The segments contain microscopic printed LEDs that are connected in parallel by two conductive layers sandwiching the LEDs. The top conductive layer is transparent. Separately formed from the light sheet segments is a flexible, large area conductor backplane having a single layer or multiple layers of solid metal strips (traces). The segments are laminated over the backplane's metal pattern to supply power to the segment terminals. An adhesive layer secures the segments to the backplane. The metal pattern may connect the segments in series, or parallel, or form an addressable circuit for a display. The segments may be on a common substrate or physically separated from each other prior to the lamination.

Abstract: A flexible light sheet includes a thin substrate that allows light to pass through it, a transparent first conductor layer overlying the substrate, an array of vertical light emitting diodes (VLEDs) printed as an ink over the first conductor layer, each of the VLEDs having a bottom electrode electrically contacting the first conductor layer, a dielectric material between the VLEDs overlying the first conductor layer, and a transparent second conductor layer overlying the VLEDs and dielectric layer, each of the VLEDs having a top electrode electrically contacting the transparent second conductor layer. Each individual VLED may emit light bidirectionally. The VLEDs are illuminated by a voltage differential between the first conductor layer and the second conductor layer such that bidirectional light passes through the first conductor layer and the second conductor layer. Phosphor layers may be deposited on both sides to create white light using blue VLEDs.

Abstract: A system of interlocking LED panel tiles includes a first tile having at least one layer of light emitting diodes (LEDs) provided on a substrate, where the substrate is mounted on a substantially rectangular supporting plate having interlocking features. The substrate overlaps the interlocking features. The first tile has a set of positive and negative voltage conductors running between the two sets of opposite edges of the tile as busses. Multiple identical tiles are provided. Each tile has the interlocking features along their edges that firmly physically connect to abutting tiles to create a lamp having any pattern of tiles selected by the user. By interlocking the tiles, the positive and negative conductors are automatically connected to electrically connect the LEDs in the tiles in parallel, and the interlocking features are hidden by the overlying substrate. Additional conductors may be used to provide greater interconnection flexibility.

Abstract: A method of forming a light sheet includes printing a layer of inorganic LEDs on a first conductive surface of a substrate, depositing a first dielectric layer, and depositing a second conductor layer over the LEDs so that the LEDs are connected in parallel. At least one of the first conductive surface or the second conductor layer is transparent to allow light to escape. A phosphor layer may be formed over the light sheet so that the LED light mixed with the phosphor light creates white light. The flat light sheet is then folded, such as by molding, to form a three-dimensional structure with angled light emitting walls and reflective surfaces to control a directionality of the emitted light and improve the mixing of light. The folds may form rows of angled walls or polygons.

Abstract: A method of forming a light sheet includes depositing a reflective conductor layer over a substrate, printing a layer of microscopic inorganic LEDs on the conductor layer, depositing a first dielectric layer, having a first index of refraction, over the conductor layer and along sidewalls of the LEDs, and depositing a transparent conductor layer over the LEDs so that the LEDs are connected in parallel. The transparent conductor layer may be a wire mesh with openings. A liquid or paste polymer layer is then deposited over the transparent conductor layer and directly contacts the first dielectric layer. The indices of refraction of both layers are similar to reduce TIR. The top surface of the polymer layer is then molded to contain light extraction features to reduce waveguiding in the light sheet.

Abstract: An initially flat light sheet is formed by printing conductor layers and microscopic LEDs over a flexible substrate to connect the LEDs in parallel. The light sheet is then subjected to a molding process which forms 3-dimensional features in the light sheet, such as bumps of any shape. The features may be designed to create a desired light emission profile, increase light extraction, and/or create graphical images. In one embodiment, an integrated light sheet and touch sensor is formed, where the molded features convey touch positions of the sensor. In one embodiment, a curable resin is applied to the light sheet to fix the molded features. In another embodiment, optical features are molded over the flat light sheet. In another embodiment, each molded portion of the light sheet forms a separate part that is then singulated from the light sheet.

Abstract: In a method for forming a phosphor-converted LED, an array of vertical LEDs is printed over a conductive surface of a substrate such that a bottom electrode of the LEDs ohmically contacts the conductive surface. A dielectric layer then formed over the conductive surface. An electrically conductive phosphor layer is deposited over the dielectric layer and the LEDs to ohmically contact the top surface of the LEDs and connect the LEDs in parallel. The conductive phosphor layer is formed by phosphor particles intermixed with a transparent conductor material. One or more metal contacts over the conductive phosphor layer conduct current through the conductive phosphor layer and the LEDs to illuminate the LEDs. A portion of light generated by the LED leaks through the conductive phosphor layer, and the combination of the LED light and phosphor light creates a composite light.

Abstract: A PV module is formed having an array of PV cells, where the cells are separated by gaps. Each cell contains an array of small silicon sphere diodes (10-300 microns in diameter) connected in parallel. The diodes and conductor layers may be patterned by printing. A continuous metal substrate supports the diodes and conductor layers in all the cells. A dielectric substrate is laminated to the metal substrate. Trenches are then formed by laser ablation around the cells to sever the metal substrate to form electrically isolated PV cells. A metallization step is then performed to connect the cells in series to increase the voltage output of the PV module. An electrically isolated bypass diode for each cell is also formed by the trenching step. The metallization step connects the bypass diode and its associated cell in a reverse-parallel relationship.

Abstract: A programmable circuit includes an array of printed groups of microscopic transistors or diodes. The devices are pre-formed and printed as an ink and cured. The devices in each group are connected in parallel so that each group acts as a single device. In one embodiment, about 10 devices are contained in each group so the redundancy makes each group very reliable. Each group has at least one electrical lead that terminates in a patch area on the substrate. An interconnection conductor pattern interconnects at least some of the leads of the groups in the patch area to create logic circuits for a customized application of the generic circuit. The groups may also be interconnected to be logic gates, and the gate leads terminate in the patch area. The interconnection conductor pattern then interconnects the gates for form complex logic circuits.

Abstract: A thin flexible light strip is formed by printing microscopic LEDs in rectangular sections along the light strip, where each rectangular section creates a vertically elongated emission profile. The light strip has a length approximately equal to the length of a shelf supporting products (e.g., bottles) to be illuminated. The shelf may be in a glass-door cooler in a store. Each section is located along the light strip to be centered with a product in the front row on the shelf. The light strip is supported by a plastic holder that attaches to the front of the shelf. The holder angles the light strip upward between 20-40 degrees, relative to vertical, to substantially uniformly illuminate each product equally. The holder may support an additional light strip that is angled downward toward products on a lower shelf.

Abstract: A layer of microscopic printed VLEDs is sandwiched between a first conductor layer and a transparent second conductor layer so that light exits the second conductor layer. Touch sensor electrodes are formed overlying the VLED layer so that the VLEDs illuminate the touch sensor. In one embodiment, the touch sensor electrodes are independent from the conductor layers for the VLEDs. In another embodiment, the transparent second conductor layer also serves as a touch sensor electrode. In another embodiment, both the conductor layers for the VLEDs serve as touch sensor electrodes. The conductor layers for the VLEDs may be segmented in groups to selectively illuminate groups of the VLEDs under each touch sensor position. The touch sensor electrodes may be transparent or opaque, depending on whether the electrodes are intended to allow the VLED light to pass through.

Abstract: A flex-circuit or a rigid printed circuit board is formed by depositing an adhesive pattern on a top surface of a substrate. The adhesive pattern corresponds to a copper foil pattern to be formed for interconnecting electronic components. A thin copper foil is then laminated over the substrate to adhere the foil to the adhesive pattern. The foil is then peeled off the substrate such that the foil overlying the adhesive pattern remains, and the foil that is not overlying the adhesive pattern is removed. In one embodiment, the foil is cut or weakened along the edges of the adhesive pattern to minimize tearing of the foil. The foil may be first affixed to a sheet for increased mechanical integrity, prior to the foil being laminated over the substrate, followed by kiss-cutting the foil while on the sheet to avoid tearing of the foil during the lift-off step.

Abstract: A system of interlocking LED panel tiles includes a first tile having at least one layer of light emitting diodes (LEDs) provided on a substrate, where the substrate is mounted on a substantially rectangular supporting plate having interlocking features. The substrate overlaps the interlocking features. The first tile has a set of positive and negative voltage conductors running between the two sets of opposite edges of the tile as busses. Multiple identical tiles are provided. Each tile has the interlocking features along their edges that firmly physically connect to abutting tiles to create a lamp having any pattern of tiles selected by the user. By interlocking the tiles, the positive and negative conductors are automatically connected to electrically connect the LEDs in the tiles in parallel, and the interlocking features are hidden by the overlying substrate. Additional conductors may be used to provide greater interconnection flexibility.

Abstract: A first layer of first vertical light emitting diodes (VLEDs) is printed on a conductor surface. A first transparent conductor layer is deposited over the first VLEDs to electrically contact top electrodes of the first VLEDs. A second layer of second VLEDs is printed on the first transparent conductor layer. Since the VLEDs are printed as an ink, the second VLEDs are not vertically aligned with the first VLEDs, so light from the first VLEDs is not substantially blocked by the second VLEDs when the VLEDs are turned on. A second transparent conductor layer is deposited over the second VLEDs to electrically contact top electrodes of the second VLEDs. By this structure, the first VLEDs are connected in parallel, the second VLEDs are connected in parallel, and the first layer of first VLEDs and the second layer of second VLEDs are connected in series by the first transparent conductor layer.