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 light-altering apparatus, comprising: a layer of a suspension matrix containing color converting nanoparticles, wherein the layer has a thickness of equal to or less than 25 ?m, and wherein the color converting nanoparticles in the layer are configured in a substantially uniform distribution, wherein an average distance dimension between neighboring color converting nanoparticles is substantially equal to a largest dimension of a largest nanoparticle, of the color converting nanoparticles, present in the suspension matrix.

2. The light-altering apparatus of claim 1 further comprising a patterning of the layer, wherein said patterning provides an optical function in addition to a color conversion function of said color converting nanoparticles of the suspension matrix, and wherein said functions are combined to form a light-altering meta-material.

3. The light-altering apparatus of claim 2 wherein said patterning performs a light diffusing function.

4. The light-altering apparatus of claim 2 wherein said patterning comprises a diffraction grating, which performs at least one light wave interference function.

5. The light-altering apparatus of claim 2 wherein said patterning comprises a distributed Brag refraction array, which performs a dichroic filter function.

6. The light-altering apparatus of claim 2 wherein said patterning comprises a prismatic light-turning structure, which performs a light steering function.

7. The light-altering apparatus of claim 2 wherein said layer further comprises at least one patternable lithography material, selected from a set of lithography materials consisting of: a NIR photo-resist, a UV photo-resist, a chemical-resist and a thermal-resist.

8. The light-altering apparatus of claim 1 wherein said color converting nanoparticles comprises at least one kind of nanoparticle selected from a set of nanoparticles consisting of: nanophosphors, nanosized quantum dots, perovskite nanoparticles, photo-dispersing nanoparticles, photo-refractive nanoparticles, nanosized chromophores, nanosized fluorophores, dielectric nanoparticles and conductive nanoparticles.

9. A meta-material apparatus comprising: at least one layer, wherein a layer consists of a suspension matrix layer containing a plurality of color converting nanoparticles, wherein the layer comprising the suspension matrix has a thickness of less than or equal to 25 ?m, and wherein the color converting nanoparticles are uniformly spaced at a distance at least equal to a largest dimension of a largest nanoparticle in the suspension matrix layer.

10. The meta-material apparatus of claim 9 wherein a layer further comprises a lithography resist material, and wherein the lithography resist material is patterned into an optical feature structure performing a light-altering functionality, in addition to a color converting function of said suspension matrix layer.

11. The meta-material apparatus of claim 10 wherein further, said lithography resist material consists of at least one patternable lithography material, selected from a set of lithography resist materials consisting of: a NIR photo-resist, a UV photo-resist, a chemical-resist, and a thermal-resist

12. The meta-material apparatus of claim 10 wherein said patterned structure comprises optical features of a Fresnel lens.

13. The meta-material apparatus of claim 10 wherein said patterned structure comprises optical features of a wire-grid polarizer.

14. The meta-material apparatus of claim 10 wherein said patterned structure comprises optical features of a bat-wing de-focuser.

15. The meta-material apparatus of claim 10 wherein said patterned structure comprises optical features of a distributed Brag refraction array, of a dichroic filter.

16. The meta-material apparatus of claim 10, wherein further a plurality of layers is combined, wherein a refractive index of the materials comprising each layer of said plurality of layers, is selected to form a distributed Bragg refractor array when said plurality of layers are combined to form a combined plurality of layers, and wherein said combined plurality of layers performs a dichroic color filtering operation, in addition to a color conversion function of at least one of the layers of the combined plurality of layers.

17. The meta-material apparatus of claim 10, further comprising a dichroic color filter layer, in addition to said suspension matrix layer, and wherein further a plurality of layers is combined to form combined layers, and wherein a color emitted by said combined layers forms a tuned light emission apparatus with emission wavelengths determined by a combination of said color converting nanoparticles and said dichroic color filter.

18. The meta-material apparatus of claim 10 wherein said color converting nanoparticles comprise a nanophosphor.

19. The meta-material apparatus of claim 10 wherein said color converting nanoparticles comprise a quantum dot.

20. The meta-material apparatus of claim 10 wherein said color converting nanoparticles comprise a photo-dispersing nanoparticle.

21. The meta-material apparatus of claim 10 wherein said color converting nanoparticles comprise a photo-refractive nanoparticle.

22. The meta-material apparatus of claim 10 wherein said color converting nanoparticles comprise a conductive nanoparticle.

23. The meta-material apparatus of claim 10 wherein said color converting nanoparticles comprise a dielectric nanoparticle.

24. The meta-material apparatus of claim 10 wherein said color converting nanoparticles comprise a nanosized quantum dot.

25. The meta-material apparatus of claim 10 wherein said color converting nanoparticles comprises a nanosized chromophore or fluorophore particle.

26. A meta-material apparatus comprising: a plurality of layers, wherein at least two layers of said plurality of layers comprises a suspension matrix comprising color converting nanoparticles, wherein each layer of said plurality of layers has a thickness of equal to or less than 25 ?m, and wherein the layers comprising color converting nanoparticles of said plurality of layers 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 a given layer, wherein at least a first layer of said plurality of layers is configured to convert a first excitation waveband of light to a first emission waveband of light, and wherein at least a second layer of said plurality of layers is configured to convert a second excitation waveband of light to a second emission waveband of light, and wherein the first emission waveband of light is different from the second emission waveband of light.

27. The meta-material apparatus of claim 24 further comprising a pattern lithographically imprinted on at least one layer of the plurality of layers, forming a patterned material layer, wherein said patterned material layer performs a light-altering function in addition to a color conversion function of at least one layer of the plurality of layers.

28. The meta-material apparatus of claim 24 wherein said plurality of layers comprises at least one characteristic selected from a set of characteristics consisting of: an excitation waveband, an emission waveband, and a dominant emission wavelength, wherein said plurality of layers outputs a complex plurality of emission wavelengths, from a given input waveband, and wherein said plurality of layers performs a complex light wavelength emission function, in addition to a color conversion function of at least one of the plurality of layers.

29. The meta-material apparatus of claim 26, wherein further a refractive index of the materials comprising each of said plurality of layers, is selected to form a distributed Bragg refractor array when said plurality of layers are combined, and wherein said combined plurality of layers performs a dichroic color filtering operation, in addition to a color conversion function of at least one of the plurality of layers.

30. The meta-material apparatus of claim 26, further comprising a dichroic color filter layer, added after an output of at least one layer of said plurality of layers forming a tuned emission wavelength layer stack.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0278] FIG. 1 is an illustration depicting the prior art of MicroLED with Color Conversion Layers FIG. 2 is an illustration depicting typical phosphor grinding process

[0279] FIG. 3 is an illustration depicting typical phosphor particles, at initial time the average particle size is 40 ?m

[0280] FIG. 4 is an illustration depicting analysis of the Nanoparticles from the described methods, with majority size less than 100 nm

[0281] FIG. 5 is an illustration depicting an example High-Speed Ball Milling processes

[0282] FIG. 6 is an illustration depicting embodiments of a Bulk Nanoparticle Sorting Apparatus

[0283] FIG. 7 is an illustration depicting a phase array color filter formed from a waveguide arranged out of functional nanoparticles

[0284] FIG. 8 is an illustration depicting 1D, 2D & 3D Bragg Diffraction structures from alternating refractive index materials (n1, n2)

[0285] FIG. 9 is an illustration depicting a Bragg Reflector formed from functional nanoparticle layers FIG. 10 is an illustration depicting a multi-modal light assembly package with differential die placement

[0286] FIG. 11 is an illustration depicting stacked spin-coated substrates

[0287] FIG. 12 is an illustration depicting microscope views of nanopatterned optical films, using red nanophosphor in SU-8

[0288] FIG. 13 is an illustration depicting nanopatterned optical film, using red nanophosphor in SU-8 FIG. 14 is an illustration depicting a patterned film incorporating Nanophosphor Particles

[0289] FIG. 15 is an illustration depicting a functional nanopatterned film Layers

[0290] FIG. 16 is an illustration depicting a functional nanopatterned film Layers

[0291] FIG. 17 is an illustration depicting a patterning on cover substrate

[0292] FIG. 18 is an illustration depicting mounting the patterned layer on the MicroLED

[0293] FIG. 19 is an illustration depicting a reduction into practice of nanopatterning with nanophosphor materials (VividColor NanoBright)

[0294] FIG. 20 is an illustration depicting a Highly-Functional Layered Thin-Film constructed from Nanopatterned Materials

[0295] FIG. 21 is an illustration depicting nanopatterning with nanomaterials

[0296] FIG. 22 is an illustration depicting an assembly of nanopatterned filter/polarizer/collimators using patterned color-particles

[0297] FIG. 23 is an illustration depicting a display with nanopatterned emissive waveguide filter/polarizer/collimator layer

[0298] FIG. 24 is an illustration depicting an electro-luminescent Display based on Cyan and optional Blue

[0299] FIG. 25 is an illustration depicting an electro-luminescent Display based on Cyan and optional Blue

[0300] FIG. 26 is an illustration depicting an electro-luminescent Display based on Cyan Excitations

[0301] FIG. 27 is an illustration depicting an electro-luminescent Display based on White Excitations

[0302] FIG. 28 is an illustration depicting a high-functionality film Electro-Luminescent Display Backlight

[0303] FIG. 29 is an illustration depicting a high-functionality film Electro-Luminescent Display Backlight

[0304] FIG. 30 is an illustration depicting an electroluminescent NP-LED pixel with B-C-G-Y-R-W sub-elements

[0305] FIG. 31 is an illustration depicting square and hexagonal sub-pixel structured NanoParticle-LED

[0306] FIG. 32 is an illustration depicting a multi-layer MicroLED with functional ray steering surface structures

[0307] FIG. 33 is an illustration depicting a batwing diffuser layer on-top-of a MicroLED

[0308] FIG. 34 is an illustration depicting LED 3D light projector and SLCS (right) surface light collimating structure

[0309] 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

[0310] 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

[0311] FIG. 37 is an illustration depicting an electrophoretic ePaper display with YAG White LED

[0312] FIG. 38 is an illustration depicting an eye-safe front lit emissive ePaper color display (without ambient light filter)

[0313] FIG. 39 is an illustration depicting nanophosphors in an electrophoretic display configuration

[0314] FIG. 40 is an illustration depicting an eye-safe front lit emissive ePaper color display

[0315] FIG. 41 is an illustration depicting an eye-safe emissive color ePaper display based on TIR mode

[0316] FIG. 42 is an illustration depicting a solar cell comprising a nanoparticle conversion layer

[0317] FIG. 43 is an illustration depicting a solar cell comprising a nanoparticle functional meta-material layer

[0318] FIG. 44 is an illustration depicting a solar cell comprising a nanophosphor band-gap

[0319] FIG. 45 is an illustration depicting a tandem solar cell using Nanophosphor and Silicon Cell

[0320] FIG. 46 is an illustration depicting a fiber-optic cable with color-converting material in distributed Bragg Grating

[0321] FIG. 47 is an illustration depicting an Image sensor pixel using nanophosphor band-gap

POST-SCRIPT

[0322] 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.

[0323] 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.