Apparatus and method for creating highly-functional meta-materials from luminescing nanoparticles

Abstract

Presented herein are methods for creating nanoparticles, which exhibit desirable electro-luminescent and photo-luminescent capabilities, while retaining the robust inorganic nature. And incorporating the nanoparticles in micron and sub-micron scale structures, via a range of patterning techniques, to create highly functional meta-material apparatus. Example embodiments include applications in emissive color elements within displays, Micro-LED devices, and thin-film apparatus; integrating optical, photonic and plasmonic properties, from the combination of patternable nano-scale features, with photo/electro-luminescing material capabilities; performing multiple light processing functions, within the apparatus. The method of construction, materials, electrical drive, color and pixel manipulation as well as system integration are described, such that one of ordinary skill in the art could construct implementations including lighting, displays, panels and other applications.

Claims

1. A functional light-converting meta-material apparatus, comprising a layer of suspension matrix, wherein the suspension layer has a thickness of less than 25 um, and wherein the suspension matrix comprises color converting nanoparticles; wherein at least one of said nanoparticles is configured to emit a non-blue photon of light responsive to stimulation of blue photon of light, wherein a monolayer of the color converting nanoparticles comprises a minimum thickness of 1 nanoparticle, wherein the nanoparticles in the monolayer form a uniform layer such that an average distance between neighboring particles is generally uniform and consistent with the largest dimension of a largest nanoparticle present in the suspension; and, wherein a resist material and the suspension are formed, via nanopatterning, into a functional material structure, creating optical functionality in addition to the materials inherent color conversion functionality.

2. The apparatus of claim 1, further comprising at least one photo-lithography resist material selected from a set of nanoparticles including: NIR photo-resist, UV photo-resist, chemical-resist and thermal-resist.

3. The apparatus of claim 1, further comprising at least one nanoparticle selected from a set of nanoparticles consisting of: nanophosphors, quantum dots, photo-dispersing nanoparticles, photo-refractive nanoparticles, and conductive particles.

4. The apparatus of claim 1, wherein a process of forming the functional material structure is one selected from a group consisting of: nanolithographic transfer, and photo-lithographic transfer.

5. A color converting apparatus comprising: a suspension matrix comprising color converting nanoparticles, wherein the color converting nanoparticles are configured to emit a photon of a second wavelength responsive to stimulation by a photon of a first wavelength, wherein the suspension matrix comprises a layer having a thickness of less than 25 ?m, and wherein the color converting nanoparticles in the layer are configured in a uniform distribution, wherein an average distance dimension between neighboring nanoparticles is substantially equal to a largest dimension of a largest nanoparticle present in the suspension matrix.

6. The color converting apparatus of claim 5 wherein said color converting nanoparticles comprise a nanophosphor.

7. The color converting apparatus of claim 5 wherein said color converting nanoparticles comprise a quantum dot.

8. The color converting apparatus of claim 5 wherein said color converting nanoparticles comprise a photo-dispersing nanoparticle.

9. The color converting apparatus of claim 5 wherein said color converting nanoparticles comprise a photo-refractive nanoparticle.

10. The color converting apparatus of claim 5 wherein said color converting nanoparticles comprise a conductive particle.

11. The color converting apparatus of claim 5 further comprising a photo-lithography resist material, patterned into a structure having optical functionality independent of a color converting function of said nanoparticles.

12. The color converting apparatus of claim 11 wherein said structure comprises a diffuser.

13. The color converting apparatus of claim 11 wherein said structure comprises a diffraction grating.

14. The color converting apparatus of claim 11 wherein said structure comprises a Brag filter.

15. The color converting apparatus of claim 11 wherein said structure comprises a prismatic light-turning structure.

16. The color converting apparatus of claim 15 wherein said structure is etched via a laser.

17. The color converting apparatus of claim 11 wherein said photo-lithography resist material comprises a UV curable photo-resist.

18. The color converting apparatus of claim 11 wherein said photo-lithography resist material comprises an infrared (IR) curable photo-resist.

19. The color converting apparatus of claim 11 wherein said photo-lithography resist material comprises a near-infrared (NIR) curable photo-resist.

20. The color converting apparatus of claim 5 wherein said etching independent of a mask.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an illustration depicting the prior art of MicroLED with Color Conversion Layers

(2) FIG. 2 is an illustration depicting typical phosphor grinding process

(3) FIG. 3 is an illustration depicting typical phosphor particles, at initial time the average particle size is 40 um

(4) FIG. 4 is an illustration depicting analysis of the Nanoparticles from the described methods, with majority size less than 100 nm

(5) FIG. 5 is an illustration depicting an example High-Speed Ball Milling processes

(6) FIG. 6 is an illustration depicting embodiments of a Bulk Nanoparticle Sorting Apparatus

(7) FIG. 7 is an illustration depicting a phase array color filter formed from an waveguide arranged out of functional nanoparticles

(8) FIG. 8 is an illustration depicting 1D, 2D & 3D Bragg Diffraction structures from alternating refractive index materials (n1, n2)

(9) FIG. 9 is an illustration depicting a Bragg Reflector formed from functional nanoparticle layers

(10) FIG. 10 is an illustration depicting a multi-modal light assembly package with differential die placement

(11) FIG. 11 is an illustration depicting stacked spin-coated substrates

(12) FIG. 12 is an illustration depicting microscope views of nanopatterned optical films, using red nanophosphor in SU-8

(13) FIG. 13 is an illustration depicting nanopatterned optical film, using red nanophosphor in SU-8

(14) FIG. 14 is an illustration depicting a patterned film incorporating Nanophosphor Particles

(15) FIG. 15 is an illustration depicting a functional nanopatterned film Layers

(16) FIG. 16 is an illustration depicting a functional nanopatterned film Layers

(17) FIG. 17 is an illustration depicting a patterning on cover substrate

(18) FIG. 18 is an illustration depicting mounting the patterned layer on the MicroLED

(19) FIG. 19 is an illustration depicting a reduction into practice of nanopatterning with nanophosphor materials (VividColor NanoBright)

(20) FIG. 20 is an illustration depicting a Highly-Functional Layered Thin-Film constructed from Nanopatterned Materials

(21) FIG. 21 is an illustration depicting nanopatterning with nanomaterials

(22) FIG. 22 is an illustration depicting an assembly of nanopatterned filter/polarizer/collimators using patterned color-particles

(23) FIG. 23 is an illustration depicting a display with nanopatterned emissive waveguide filter/polarizer/collimator layer

(24) FIG. 24 is an illustration depicting an electro-luminescent Display based on Cyan and optional Blue

(25) FIG. 25 is an illustration depicting an electro-luminescent Display based on Cyan and optional Blue

(26) FIG. 26 is an illustration depicting an electro-luminescent Display based on Cyan Excitations

(27) FIG. 27 is an illustration depicting an electro-luminescent Display based on White Excitations

(28) FIG. 28 is an illustration depicting a high-functionality film Electro-Luminescent Display Backlight

(29) FIG. 29 is an illustration depicting a high-functionality film Electro-Luminescent Display Backlight

(30) FIG. 30 is an illustration depicting an electroluminescent NP-LED pixel with B-C-G-Y-R-W sub-elements

(31) FIG. 31 is an illustration depicting square and hexagonal sub-pixel structured NanoParticle-LED

(32) FIG. 32 is an illustration depicting a multi-layer MicroLED with functional ray steering surface structures

(33) FIG. 33 is an illustration depicting a batwing diffuser layer on-top-of a MicroLED

(34) FIG. 34 is an illustration depicting LED 3D light projector and SLCS (right) surface light collimating structure

(35) FIG. 35 is an illustration depicting a prior are TIR ePaper display, wherein a TFT field moves particles that interfere with the Total Internal Reflection to effect a change in a pixel's light reflection/absorption

(36) FIG. 36 is an illustration depicting prior art electrophoretic ePaper based on moving monochromatic (light-absorbing/reflective) ink particles in a microcapsule in an electric field

(37) FIG. 37 is an illustration depicting an electrophoretic ePaper display with YAG White LED

(38) FIG. 38 is an illustration depicting an eye-safe frontlit emissive ePaper color display (without ambient light filter)

(39) FIG. 39 is an illustration depicting nanophosphors in an electrophoretic display configuration

(40) FIG. 40 is an illustration depicting an eye-safe frontlit emissive ePaper color display

(41) FIG. 41 is an illustration depicting an eye-safe emissive color ePaper display based on TIR mode

(42) FIG. 42 is an illustration depicting a solar cell comprising a nanoparticle conversion layer

(43) FIG. 43 is an illustration depicting a solar cell comprising a nanoparticle functional meta-material layer

(44) FIG. 44 is an illustration depicting a solar cell comprising a nanophosphor band-gap

(45) FIG. 45 is an illustration depicting a tandem solar cell using Nanophosphor and Silicon Cell

(46) FIG. 46 is an illustration depicting a fiber-optic cable with color-converting material in distributed Bragg Grating

(47) FIG. 47 is an illustration depicting an Image sensor pixel using nanophosphor band-gap

POST-SCRIPT

(48) The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as may be suited to the particular use contemplated.

(49) Embodiments according to the invention are thus described. While the present disclosure has been described in particular embodiments, it should be appreciated that the invention should not be construed as limited by such embodiments, but rather construed according to the below claims.