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AU2013101680A4 - Faultless High Efficiency Illuminator - Google Patents

Faultless High Efficiency Illuminator

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AU2013101680A4
AU2013101680A4 AU2013101680A AU2013101680A AU2013101680A4 AU 2013101680 A4 AU2013101680 A4 AU 2013101680A4 AU 2013101680 A AU2013101680 A AU 2013101680A AU 2013101680 A AU2013101680 A AU 2013101680A AU 2013101680 A4 AU2013101680 A4 AU 2013101680A4
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illuminator
led
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high efficiency
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AU2013101680A
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Laurence Faget
Michael Snowden
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Abstract

The disclosed High Efficiency Illuminator is an improvement on prior art Illuminators for mostly indoor use, where a GaN-on-GaN high efficiency high brightness LED light source is the preferred light source for use in electric lighting fixtures used in for example: illumination in or on buildings, structures, chattels, vehicles, and areas where general indoor lighting is required from an electrical lighting device, where the Illuminator(s) has a predominately fixed orientation of illumination with respect to its Fixture's mounting position and where such an Illuminator(s) may be mated to a prior art Fixture's pre-existing lamp socket(s) either directly or via an appropriately designed adaptor. The Invention utilizes GaN-on-GaN high efficiency high brightness LED(s) which greatly reduces the internal faults affecting light producing regions/layers of the LED(s) over conventional prior art high brightness LED(s) to provide a much higher light emission density which in turn produces a high efficiency Illuminator with over 4 times higher light output densities compared to prior art LED Illuminators. Through the use of GaN-on-GaN LED(s), the high efficiency Illuminator is kept compact in physical size as well as efficient in power requirements.

Description

AUSTRALIA Patents Act 1990 Complete Specification Innovation Patent Faultless High Efficiency Illuminator The following statement is a full description of this Invention, including the best method of performing it known to us: 1 Background The most recent prior art in the field of High Efficiency Illuminators are built with High Brightness LEDs (HB LED) as their main illumination component. The improvements in moving to HB LEDs from prior art technologies such as: Incandescent, Halogen, Xenon, and Metal halide, are the higher efficiencies of HB LEDs and their considerably longer lifetimes of 30~5000 hours for HB LEDs vs 10~1000 hours for most common prior art technologies. As the push for "Green" technologies and higher efficiencies continues, LED lighting is clearly the direction for the lighting world. Prior to the year 2000 there were slow incremental improvements in pre-LED technologies, but in the past 10 or so years the technology improvements in non-LED prior art technologies has approached and slowed to a point that there is now little room for improvements on a viable commercial scale. For example, the Inventors have used commercial, type "FCR" 12 volt 100 watt halogen globes in their business since 1979 and their has been no change in performance or specifications in the past 35 years, except for the introduction of an Infra-red reflecting coating on the front of the globe to internally reflect heat back into the globe to increase efficiency. In essence the field of non LED lighting technologies have reached their practical limit, and nearly all new Research and Development is focussed on the LED market. Looking at lamps more closely, lamps are typically constructed in predominately two different ways. For example, those which are permanently attached to a Fixture, and those which are removably attached to a Fixture. The latter type are mostly fitted to the Fixture via a lamp socket(s) type connector (to be removably attached) and are designed to have for example, a male plug type connector mate to a matching female socket type connector, which provides an electrical connection to the lamp and supports it in the Fixture. The use of Fixture sockets allows lamps to be mostly safely, conveniently, and easily changed out at end of life or as needed. There are many different standards for these connector sockets, created by de facto and by various "Standards Bodies" (eg: International Electrotechnical Commission (IEC), 2 International Organization for Standardization (ISO), American National Standards Institute (ANSI), and others. Some of the more commonly used lamp bases in Australia are: the Edison Screw (ES) mounts E-14, E-26, E-40, Bayonet Cap (BC) mounts B15, and B22, Halogen types, GU5.3, GU4, GY6.35, Fluorescent tube types such as the T12 and T5 are shown with some dimensions and orientations. Of all of these styles, the BC B22 (or sometimes BA22d) is the most widely used socket in Australia for incandescent and compact florescent lamps (CFLs). Other examples of lamps with Bi-Post and Bi-pin connectors (e.g. 2 pins) (e.g. T-5, T-12 found on florescent lamps), halogen type (e.g. bi-pin G4, G5.3, G6.35), and twist lock GU type halogen lamps connectors shown on the example of a GU-10 Dichroic down light lamps of. The examples given are not exhaustive of the lamp base types available. It is also stated at this point that Illuminators of "MR1 6" design are not part of this Invention. Many prior art lamp sockets require careful attention when fitting and removing lamps. They are common place in buildings, structures and vehicles but may also pose a risk to the personnel replacing the lamp as contact to "live" and sometimes, dangerous voltage (where high voltage mains supply is present) sometimes occurs which can cause serious injury or even death. Most modern prior art LED Illuminators utilize low voltage requirements and may be designed such that the Illuminator, as well as any Illuminator socket, limits dangers associated with high voltage devices and early art lamp sockets. Some "heavy duty" prior art lamps were fitted to their fixtures more securely. Instead of a simple "twist and lock" or screw in type fitment (eg: BC and ES) these sealed lamps were attached to their mountings by clamps, springs and cover rings to securely attach the lamps. Even the wires were attached by screw terminals. These lamps were used in predominately outdoor Fixtures or for stage lighting as well as on vehicles. 3 Suffice to say that there are many different styles and variations of these sockets and plugs and the examples mentioned here are not limiting the designs available, and those knowledgeable in the art would be aware of their designations and intended uses. In most prior art retrofit LED Illuminators, the Illuminator's LED lamp(s) is/are usually "lifetime" permanently fitted to the Illuminator. In this scenario, the Illuminator's LED lamp(s) is/are fixed by a permanent means, usually attached by screws or an appropriate adhesive to the Fixture, and the Illuminator is usually not removably attached. If the Illuminator's LED lamp(s) needs to be replaced, it is a simple matter to replace the complete Illuminator including the lamp(s). An electric Illuminator requires an electrical connection to an electrical power source. In a permanently fixed Illuminator, this is mostly achieved by a direct connecting of wires (or conductors) from the Illuminator to the Fixture, and in turn to a Power Control Module (PCM), switch or dimming module and/or a fixed power supply/source e.g. 230/240v ac household electric supply, whereas a removably attached Illuminator may have a removably attached connection (e.g. a socket-plug combination. It is suffice to say, there must be in most cases at least some degree of control from an electrical or electronic module to allow for a modification to the power supply form(s), and/or current(s) and/or voltage(s) to the LEDs if only to be able to adjust voltage for ageing of the HB LED(s) or to turn on/off or attenuate/dim the HB LED(s) for a particular environment, mood or function. The module that is used to "control" to a degree the power to the HB LED(s) Die(s) is, for the purpose of description, called a PCM. LED Illuminators usually require a specialised PCM to modify the power supplied to a form required by the LED(s) and may be attached adjacent or close to the LED in the Illuminator or Fixture. Some LEDs are able to be connected directly to a power source without any special PCMs, e.g. Tesla ac LEDs. Illuminators may also have a PCM, remote from the Fixture and Illuminator to supply the correct power form to the Illuminator or to control the light output from the Illuminator(s). 4 Lamp manufacturers have strived for higher efficiency in their devices. Prior art HB LED Illuminators are readily available and their most evolved efficiency rivals that of other high efficiency lamp technologies with respect to their efficacy (eg: High Intensity Discharge (HID) lamps with efficacy of 90-1501m/w, but mostly around 1001m/w). An modern 600w HID lamp is capable of emitting about 90,0001m. Common, commercially available, mass produced, conventional HB LEDs also have an efficiency of about 1 001m/w. Though some new models recently released (2012) are about 1301m/w (eg: Cree XP-G2), they are relatively new to the market. Sometimes a power supply module, additional to the mains power supply may be utilised or required to modify the mains power to a usable or safe form as required by the LED(s) of the Illuminator (e.g. a simple 240v to 12v step down isolating transformer), but the Power Supply Module is not necessarily integral to the Illuminator housing, but may be connected mostly any place in circuit between the main power supply and at least one of the Illuminator's LEDs. The power supply module may be a part of the Illuminator, part of an adaptor connected between the Illuminator and Fixture, a part of the Fixture, or remote to the Illuminator and Fixture. As increases in light output and efficiency are continually sort by lamp manufacturers, modern prior art HB LED Illuminators have quickly become the preferred lighting source of today. For example, their Green Credentials are preferred over prior art, eg: incandescent and HID lamps. However, there are limitations to light density output in prior art HB LEDs. We now define the type of GaN-on-GaN HB LED used in the invention as being an LED containing "non-laser GaN-on-GaN HB LED dies" collectively referred to now as "GaN-on-GaN HB LED" dies. Improvements have been made recently in the High Brightness (HB) LED(s) arena. GaN-on-GaN HB LEDs have been shown to have brightness increases of over 400% on current technology conventional HB LEDs of similar size. This is a large jump in light output densities for LEDs. This increase allows for greatly improved lighting 5 designs. Importantly, this Invention teaches how to use these GaN-on-GaN High Brightness LED(s) (HB LED(s)) in High Efficiency Illuminators. The High Efficiency Illuminator is a significant improvement on prior art electric Illuminators used in Lighting Fixtures that are commonly used indoors in buildings, structures and places where a fixed orientation illumination is required from a light source or Illuminator to illuminate for example, a space or surface, and to add extra light, in addition to that which is natively available, at times of nil or low ambient light conditions. Eg: during times of precipitation or at nighttime. Such prior art Illuminators mostly "burn" steadily when required, and provide illumination predominately to aid in human movement and endeavour, safety and comfort, or where there is a required and/or regulated function. Additionally, the High Efficiency Illuminator described is not limited to just indoor use. Typical examples of the types of prior art lamps related to the Invention are found in room lights, table lamps, pendant lights, and the like. These "Lighting Fixtures" as we refer to them, are usually of a basic or simple design (In its simplistic form, for example a single piece Illuminator, but they could be complex, for example a multi lamped Chandelier). Electric Lighting Fixtures may be fixed and permanently wired to the building, or, as by way of examples of two Table Lamps, having a power cord to connect to a power supply wall socket so that this type of Fixture is usually movable and not permanently fixed to any one position and so being not a true "Fixture" as such but rather a movable Fixture, is considered to be included within the scope of the Invention. Lighting Fixtures that are mostly fixed to, for example, a location, building, or structure by screws, chains, tethering cable or other mechanical means, and movable "Fixtures" such as desk lamps which are not usually permanently fixed to one location. All these examples of Lighting Fixtures have the illumination(s) from their Illuminator(s) in a predominately fixed position and orientation with respect to their Fixture. That is to say the Illumination(s) from the Illuminator(s) has a fixed orientation when installed that is fixed with respect to the Fixture's mounting or base. When the illumination from an Illuminator(s) is movable with respect to their Fixture's mounting or base, then these Illuminators are not considered to be included in the 6 scope of the Invention. Examples of Fixtures which when operationally installed that have a movable illumination orientation with respect to their Fixture's mounting position or base are adjustable Spotlights, adjustable "down lights", as well as adjustable desk lamps having an Illuminator that can be tilted, swivelled or rotated relative to the base of the Fixture, when installed and where the base of this "Fixture" is usually fixed. Additionally, Illuminators whose primary function is to be predominately used for a Conspicuity, Spotlight, or signalling purpose are not intended to be included and are not referred to as being included in the Invention. For reference herein, a Conspicuity Device as referenced above is a lighting device which usually when operationally active, emits light of a clearly noticeable and visibly discriminating nature (eg: flashing light) to attract the attention (by being Conspicuous) of a human observer to the said Device (eg: itself). A Spotlight on the other hand is usually a lighting device which is designed to have a movable illumination element to direct illumination to a specific thing or surface. In other words, to direct an observers attention not to itself (as does the Conspicuity light) but instead, to the spotlights target of illumination. Signalling purpose Illuminators use light to signal an observer of an intention, danger, position or direction or to give direction, notice or instruction usually to a human observer. The Illuminator, as described herein, is defined as that part of a Lighting Fixture or device that is the manufactured module or element which creates the light emission. In prior art, the Illuminator was often called the light bulb. A Lighting Fixture may be made up of only a single independent Illuminator (eg; only one element being the Illuminator) or multiple elements. The operational entity, being a single or multi element entity is referred to as an operational Lighting Fixture. In other words, if the Lighting Fixture is made of only one element then that element is the Illuminator itself. A standard prior art HB LED device usually requires Optics to concentrate the HB LED emitted light into a shaped beam. The Optics may be in the form of a Reflector(s), a Lense(s), or a combination of these. When a reflector is used it is usually of a predominantly parabolic shape made of either vacuum metallized 7 injection moulded plastic or aluminium, or spun or pressed aluminium which may be anodized and/or polished and/or vacuum metallized. Some reflectors are even made of glass when the requirement is for high heat resistance and specialized optical coatings. In certain models of prior art devices, multiple HB LEDs are used, and in these cases each HB LED may have it's own reflector and/or optics which may be either separately mounted to each HB LED or plastic moulded in a group to enable easy assembly and alignment. In the case where lense optics are used, a design using Total Internal Reflection (TIR) is commonly used to focus the output beam narrowly and efficiently, as well as reducing the overall optics size. This special type of lense uses TIR to act as both a reflector and a lense thus minimizing overall dimensions. A recent development in the area of Non Imaging Optics is the Simultaneous Multiple Surface (SMS) design method. Use of this fairly complicated and heavily mathematical method can result in almost 100% maximum light control to very narrow angles. There are various types of SMS method, but in many cases of a prior art device, the small angles sometimes sought (say 5-10 degrees) result in very large lenses in the order 20 to 25 size multiples of the original HB LED's diameter as well as very significant thicknesses. This poses significant manufacturing problems, let alone difficulties for most final end users ending up with an unwieldy and heavy end product. In respect to the actual method of LEDs producing light, we describe now some methods of LED production. The majority of the world's current HB LEDs are made using epitaxial techniques, such as Metal Organic Chemical Vapour Deposition (MOCVD), and revolve predominantly around Gallium Nitride chemistries. Chiefly amongst the epitaxial techniques is the use of a non-native substrate as the starting "base" in the epitaxial process. ("Non-native" refers to the substrate base as being not of GaN). Typically this is Sapphire in the form of (A1 2 0 3 ), Silicon Carbide (SiC), or recently Silicon (Si). 8 Sapphire is currently the most commonly used substrate base for production of GaN type LED as it is relatively cheap. Silicon Carbide is more expensive but produces a higher quality LED, however its use is limited by patent licensing restrictions. Silicon is also very cheap, and its use as a base substrate for GaN LED production mostly revolves around the fact that the world's electronic industry is primarily based on Silicon wafer fabrication, and the excess capacity in the industry is very attractive to LED manufacturers. Each of these three substrate bases have benefits and drawbacks primarily due to the mismatch of GaN grown on these substrates and the resulting epitaxial defects such as threading dislocations and stacking faults, in addition to the non-trivial production of numerous layers required in the epitaxial process of GaN LED production for transition to the light producing layer. The primary crystal plane that these GaN LEDs grow and in their direction of growth (90deg to growth) is the C plane. Whilst it is the main plane grown by manufacturers it does have many limitations. Typical critical figures obtained by LED manufacturers in the production of C-plane HB LEDs on non-native substrates are: GaN on SiC GaN on A1 2 0 3 GaN on Si Lattice constant mismatch: 3.5% 14% 7% Dislocation density: 1x10 9 /cm 2 5x10 9 /cm 2 1x10 11 /cm 2 Thermal conductivity: 1.3 W/cm-K 1.2 W/cm-K 1.0 W/cm-K As can be seen from the figures above, there is a considerably high lattice mismatch when Sapphire or Silicon is used, and less so when Silicon Carbide is used. Lattice mismatch in the epitaxial production of thin film GaN LEDs leads to high dislocation densities, low internal quantum efficiency, and reduced reliability. A significant limitation to the efficiency of GaN LEDS is the non-thermal rollover at higher current densities, leading to "Droop". "Droop" in the LED industry refers to the tendency of LEDs to decrease efficiency as current increases past a certain point. The typical best industry figures are a few amps/cm 2 with current prior art technology, 9 before significant Droop takes over. Past this value and efficiencies can drop 25% or more and quickly lead to irreversible damage to the LED dice. This is the current stage of the prior art in the efficacy (light) of HB LED's used in High Efficiency Illuminator. Recently, high quality bulk GaN substrates grown by methods such as Hybrid Vapour Phase Epitaxy (HVPE) and Liquid Phase Epitaxy LPE) have become commercially available. These bulk GaN substrates are typically grown in boules from which thin wafer slices are cut-off for use in LED epitaxy. Growth of LEDs on these native bulk GaN substrates, referred to as GaN-on-GaN, can result in very dramatic improvement in: lattice constant mismatch, thermal conductivity, quantum efficiency and current densities. Increased current densities results in reduced size LED dice, which in turn can lead to almost a point sized light source. By way of definition, reference to GaN-on-GaN HB LEDs refers to non-laser type GaN-on-GaN types HB LED, and reference to GaN and GaN-on-GaN both refer to GaN type III nitride chemistries, unless otherwise stated. The disclosed High Efficiency Illuminator of the Invention is a significant improvement on prior art High Efficiency Illuminator. HB LEDs grown on native GaN substrate will be the preferred light source (Illumination component) for High Efficiency Illuminators, and do not suffer many of the internal in-efficiencies of prior art non-native substrate grown GaN HB LED. The High Efficiency Illuminator of the Invention uses a non laser GaN-on-GaN HB LED(s) which contain at least one non-laser GaN-on-GaN HB LED die(ce). The Invention teaches those skilled in the art how to produce a more efficient High Efficiency Illuminator. 10 Benefits of the Invention As LED technology is rapidly gaining momentum as the "Green" and preferable lighting source for today and the future, this technology is the most preferred for its Green Credentials. A more efficient battery powered High Efficiency Illuminator requires less and smaller disposable or rechargeable batteries. A GaN-on-GaN HB LED can produce over 400% more light for the same LED die size as a prior art conventional HB LED, and so there are benefits that are recognised. The use of State of the Art GaN-on-GaN HB LED Technology has a multi-pronged advantage over the use of prior art light source technologies. Firstly, High Efficiency Illuminator with large reflectors can be considerably reduced in size as the smaller GaN-on-GaN HB LED die size allows for much reduced optics size to obtain a similar optical efficiency. A parabolic shaped reflector is often used in High Efficiency Illuminators. A simple general Cartesian equation of a parabola can be expressed as y=a*x 2 , with the height being expressed as y, and the width as x. Because of the squared relationship between y and x, reducing the LED die horizontal cross-section by 0.5 (by use of a GaN-on-GaN HB LED) gives a 0.52=0.25 of the original height- ie: reflector height is only 25% of original, and diameter is 50% of the original. Thus, a High Efficiency Illuminator's reflector diameter can be halved and its height reduced by , for the same output of light as a prior art High Efficiency Illuminator. Secondly, when a GaN-on-GaN HB LED has a higher lumen output density over prior art LEDs of similar size, then designs associated with that GaN-on-GaN HB LED may lead to reduced thermal design challenges. GaN-on-GaN HB LED die(ce) of the same brightness as prior art HB LED die(ce) often require a smaller heat sink design which reduces thermal design criteria when used in the High Efficiency Illuminator. Often there are also the benefits of lower heat management requirements. 11 Thirdly, the Invention allows for a much higher brightness than ever before for the same size LED light source, whereby this gain is achieved without normally increasing the physical size of the LED, the High Efficiency Illuminator, and/or the optical components, but rather by increasing the light density output of the light source, in this case using the High Efficiency Illuminator. Fourthly, the reduced size of a GaN-on-GaN HB LED Chip when compared to a similar brightness prior art conventional HB LED Chip allows for a relatively more compact LED footprint size if needed. The more efficient GaN-on-GaN HB LED die(ce) can replace multiple prior art single die HB LED die(ce). In the field of High Efficiency Illuminators as of April 2013, no High Efficiency Illuminators utilizing one or more GaN-on-GaN HB LED die(ce) in an LED emitter(s) is known to the Inventors. The flexibility of optical design from the increased light density of GaN-on-GaN HB LEDs can decrease the power requirements of a Faultless High Efficiency Illuminator, and assists the manufacturer in reducing physical size, heat sinking requirements and high current electronic PCB circuit design. Detailed description and preferred embodiments The disclosed Invention uses a GaN-on-GaN HB LED die(ce) as a source of Illumination. Elaboration of the Invention's GaN-on-GaN HB LEDs and their use is necessary to appreciate the fundamentals of the Invention and their relation to the prior art. GaN-on-GaN HB LEDs have been shown to have brightness increases of over 400% over current technology conventional HB LEDs of similar size. That is, a similar light output is emitted from a GaN-on-GaN HB LED die that is over four times smaller than the conventional HB LED die. 12 A HB LED die(ce) emitting area reduced in the order of 75+%, results in a die(ce) width reduction of about 50+%. Such a reduction in a HB LED's die(ce) size makes for very significant reductions in optics size, as well as increased efficiencies in light beam output and control. Reduction of a HB LED's die size makes for optical design that approximates classical design methods as the light source size approximates a point size more significantly than any other light source prior. As an example, a GaN-on-GaN HB LED dice of about 500 lumens output may be only 0.8mm x 0.8mm in size (length x width), which compares very favourably against other HB LED, metal halide, halogen, xenon etc. type light sources which have a light source of 3-5 times increased size over a GaN-on-GaN HB LED dice. A similar and often more complex problem exists when lense optics are used, and in general the larger the reflector(s) and/or the lense(s) optics relative to the dimensions of the light emitting area, the tighter the beam output and the more efficient is the output. The use of GaN-on-GaN HB LEDs as the light source in the Invention's High Efficiency Illuminator allows for the optical problems to be significantly reduced or virtually eliminated by the inherent nature of the smaller GaN-on-GaN HB LED die'(s) physical widths relative to prior art HB LEDs, resulting in increased light efficacy (lumens), higher quality light beam spread, and reduced optics sizes. As of February 2013, commercially available Non Laser LEDs are of a "Polarized effect" design. The LED chip die(s) are produced on wafers in a semiconductor production facility by epitaxial techniques. The "C" plane is the normal and easiest plane orientation for a LED manufacturer to make and slice off the individual LED wafer/dies from, as it is the normal direction of crystal growth. However, C-axis plane sliced wafers grown on non-native substrates exhibit a high polarization effect on the resulting LED die(s). This high polarization effect has to date, reduced the efficiency and increased the thermal problems of current LEDs. The field of semi-conductor fabrication and crystal growth in LED substrates is very complex in the science of physics and chemistry and is on-going in development, and so a brief description 13 follows as those knowledgeable in the art will appreciate the performance in efficiency improvements in GaN-on-GaN HB LEDs, the improvements therein, and their basis in epitaxial LED wafer production. Fundamentally, prior art HB LED die(ce) suffer from in-efficiencies in light production due to internal inefficiencies, defects and dislocations within the HB LED die's active light producing region(s). One cause of the inefficiencies is the "piezoelectric induced and intrinsic polarization" (Polar) effects in type III-nitride-based (eg: Gallium Nitride (GaN)) crystal structures which have typically been grown on a C-plane type substrate which creates "Polar" electric field effects within the resulting structure. The typical growth process of creating prior art HB LED die(ce) using a C-plane type substrate (eg: Silicon Carbide, Sapphire) structure can create strong intrinsic and induced electric fields (piezoelectric) within the die structures (including the light emitting active regions), and reduces the ability to produce light emission from the die's active region(s), i.e. by the Quantum Confined Stark Effect (QCSE) within quantum wells. One way of significantly reducing the many dislocations and defects, is by growing the devices on native substrates- ie. Bulk GaN substrates of a type III-nitride-based structure instead of the more commonly used non-native substrates. Epitaxial layers that are laid down epitaxially are the same to one another, so the crystal(s) have reduced threading dislocations and lattice constant mismatch, and increased thermal conductivity. Typical critical figures obtained by LED manufacturers in the production of C-plane HB LEDs on native GaN substrates are (with non-native A1 2 0 by way of comparison): GaN-on-GaN GaN on A1 2 0 3 Lattice constant mismatch: 0% 14% Dislocation density: 10 4 -5x1 0 6 /cm 2 5x1 0 9 /cm 2 Thermal conductivity: 1.3 W/cm-K 1.2 W/cm-K By utilizing a GaN-on-GaN HB LED, the lattice constant mismatch is reduced to 0%, ie. Zero faults, ie. "Faultless" and hence the Invention's name. Dislocation (and 14 defect) density is also reduced to10 4 ~5x10 6 /cm 2 , an increase in defect reduction of 1,000+ fold, (3~4.5 levels of magnitude), resulting in increased lumen efficacy, greater lumen density in the range of 400%+, minimal droop at high temperatures and currents, increased heat resistance and minimal colour shift. It is noted that a Faultless High Efficiency Illuminator may use a coloured output non white light emitting HB LED that uses other chemistry mixes, including alloys of Gallium. Eg: Infrared LEDs may use Gallium arsenide (GaAs) or Aluminium Gallium arsenide (AIGaAs); or where a UV emitting HB LED may use Aluminium Gallium Indium Nitride (AIGaInN), a yellow HB LED may use Aluminium Gallium Indium Phosphide (AIGaInP) in its active layer(s). The most common "colours" are infrared, red, orange, yellow, green, blue, violet, and ultra violet (UV). To keep the descriptions brief we refer to typical structure types and alloys/mixes where Gallium is used, as GaN "type" structures. There are many other type III-nitride chemistries, including alloys of Gallium, that may be used to produce different coloured light emissions, as well as the combined use of multiple LED die(ce) of different output colours that may be individually powered to produce a variable coloured light as desired. The descriptions and examples given should not limit the scope of the Invention in any way. The Faultless High Efficiency Illuminator is predominately for indoor use in, for example, homes, buildings, and structures and where the body of a Lighting Fixture may comprise of one or more elements where at least one of the elements comprises an Illuminator. The method of attachment of the said elements will usually be by a means using screws, clips or adhesive, socket or combination of these. The first preferred embodiment of the Invention has a Bayonet cap plug, a housing with a heat sink element with many fins, an inner place/surface to mount the PCM PCB, an LED Lamp Module, which has an inner mounting surface to mount the LED lamp's PCB which comprises the GaN-on-GaN HB LEDs, an optics element (reflector) which doubles as a protective outer housing portion and Illuminator cover. In the second preferred embodiment of the Invention, the LED Lamp module/housing has an attached LED lamp PCB which has a plurality of non-Laser GaN-on-GaN HB 15 LED(s) attached to the Lamp PCB. The Lamp PCB is attached to the LED Lamp housing's inner surface by way of permanent screw(s) means utilising and in addition to, a thermally conductive compound (such as Arctic Ceramic adhesive), to enable a safe, secure, thermally managed and operated Illuminator. The said housing houses the LED lamp (which includes PCB and LEDs) and would be securely fixed to the base section of the Illuminator. The base section of the Illuminator contains the Illuminator's plug connector (in this case a Bayonet Cap BC22 plug connector), the heat sink elements shown here as fins around a central core. The electrical connections of the Illuminator would normally be made by wires internal to the base sections and be connected to the PCM's PCB which is secured in the core of the base section. The electrical connections would be also connected from the PCM PCB to the Lamp PCB via conductors or wires. The body of the housing would normally be flat or could be slightly shaped, preferably constructed of an aluminium alloy and have attached a series of external heat dissipating elements acting as heat sinks, to aid in removing excess thermal energy from the rear of the non-laser GaN on-GaN HB LED(s), either passively or actively, via the PCB, the housing, the base sections to the environment. Being preferably of an aluminium alloy, (but could be a thermo-set or thermo-plastic material, eg: a thermally conducting plastic polymer containing metal filling, or polyfluorene or polyphenylene) the housing and base sections of the embodiment, have an extremely high thermal conductivity and emissivity due to the inherent properties of aluminium and its alloys, especially in the anodized state. The housing would typically be moulded using a die-casting technique, (but could just as easily be press stamped in some designs). The housing would also have an inlet aperture/hole for a power cable to transfer power to the GaN-on-GaN HB LED(s) via an electrical cable(s), and additionally may have an aperture(s)/hole(s) for providing a means for switching the Illuminator to its On/Off or various other states, and an aperture(s)/hole(s) to allow for thermal expansion and contraction of gas(es)/fluid(s) within the housing, or a relief mechanism/valve to assist in maintaining stress relief of gas(es)/fluid(s) within the housing. The design and materials used in the Illuminator would take into account the environment that the Illuminator is to be used in, eg: an Illuminator used 16 predominately in a position which is exposed to the elements or the weather, normally would be designed to have an Ingress Protection rating, for example, no less than IP61. The "IP" Code (Ingress Protection Rating, sometimes also interpreted as International Protection Rating) consists of the letters "IP" followed by two digits or one digit and one letter and an optional letter. As defined in international standard IEC 60529, IP Code classifies and rates the degrees of protection provided against the intrusion of solid objects (including body parts like hands and fingers), dust, accidental contact, and water in mechanical casings and with electrical enclosures. As the life of the Faultless High Efficiency Illuminator is usually of a longer lifetime than prior art Illuminators, cleaning cycles may have an important influence on performance. Cleaning of a standard prior art Fixture is usually done at the time of the (more frequent than a Faultless High Efficiency Illuminator) Illuminator replacement. It would be a desirable inclusion of a preferred embodiment of the Faultless High Efficiency Illuminator to increase the IP rating to allow for reduced cleaning cycle requirements. With little or no apparent need to change the Illuminator, there is little or no need to access the internals of the Illuminator and so in theory, the Illuminator could be sealed. This would improve the maintenance cycle as there would be less accumulated dirt (eg: dust, insects, mould, moisture or condensation) ingress and hence reduced cleaning times. To further facilitate this, the Illuminator would need to be kept "clean" for much longer periods and appropriate external surface shapes, textures and coatings may additionally be considered to enhance this feature in the Faultless High Efficiency Illuminator design. In a third preferred embodiment, the base of the Illuminator has an external component that is shaped to fit a Fixture's socket. The Illuminator connector or male "plug" is designed to mate with a female "socket" connector, for example, to facilitate the relatively simple replacement or removal process for the Illuminator at end of life, and allows the attachment to the corresponding or mating "socket" of the Lighting Fixture. There are many (Illuminator) sockets used in prior art Fixtures and the preferred embodiment is not intended to limit the scope of the Invention. The plug's external surface would be preferably of an aluminium alloy to aid in heat transfer, and constructed of similar properties as the Illuminator's housing design of the earlier 17 mentioned preferred design and material. This prior art plug allows for a replacement of a prior art lamp by a new art GaN-on-GaN HB LED(s) Illuminator. The new Illuminator would need to be able to work in a prior art Fixture without any major changes to the prior art Fixture or its power supply. The design, for example, of the Illuminator's shape and power usage would take this into consideration when used for this purpose. In the earlier described embodiment, the Illuminator has a cover that covers a portion of the housing and parts and is so designed to permit transmission of light from the Illuminator's LEDs as well as offer some mechanical protection to the internals of the Illuminator. This embodiment of the Illuminator would have an almost "clear" cover to allow for light transmission to the outside, but more likely to have a cover with at least some degree of diffusion quality or translucent property to produce a more preferred light output. The shape of the cover is mainly flat or at least, slightly shaped to match the preferred contour of the Illuminator and it's parts, including for example, the optical element. It should be stated that some covers may not intentionally be shaped "optically" and are for pure mechanical protection from the environment. Some covers may actually be shaped so as to wrap around a portion of the Illuminator housing. In the second preferred embodiment, this is a slightly translucent light diffusing cover of a bulb like shape covering the portion of the Illuminator which houses the GaN-on GaN HB LED(s) of the Faultless High Efficiency Illuminator and is so designed to permit transmission of a diffused light from the Faultless High Efficiency Illuminator as well as offering some mechanical protection. A portion of the(se) cover(s) could be clear, for example, but more likely having a portion slightly translucent or slightly textured and that some degree of translucency is preferred over a pure "clear" cover, though a clear cover with little or no diffusive properties may be used for maximum light transmission. "Clear" is defined in respect of the front cover as being relatively transparent to the preferred light colour temperature/wave-length that is generated by the GaN-on-GaN HB LED(s), and translucent is defined as having a relative opacity to which light is not allowed to pass through of no more than 55 opacity units measured on a linear scale of 0 to 100 18 opacity units (where O=transparent/clear and 1 00=opaque/blocked) and not so opaque that the transmission of light is no longer effective for the intended application. It is appreciated that there can be an infinite number of cover shapes, some of which may incorporate light output modifying optics, and even tints or engineered coatings, and so it is stated simply that the preferable materials for the front transmission window or cover would be preferably selected from an Ultra Violet (UV) stabilised polycarbonate (sheet or injection moulded), tempered glass, cellulose butyrate or propionate (for petrochemical protection). One particular embodiment could use for example a photo phosphor containing resinous layered cover to act as a wavelength changing medium to allow light of a predominately different wavelength to emit rather than that of the GaN-on-GaN HB LED(s) itself. (This is commonly referred to as a "remote phosphor" filter and would normally only be used in the absence of a photo phosphor layer, or doping layer being absent from the GaN-on-GaN HB LED die(ce)). Another embodiment would have a cover manufactured from a normally clear resinous substance, so moulded to be integrally/intimately attached or moulded onto the GaN-on-GaN HB LED(s) and encase the GaN-on-GaN HB LED(s) partly or as a whole. The resinous encasing/cover described could act for example, as an optical light shaping member as well as being of a protecting nature. Looking again at the thermal management of the Illuminator, the heat conduction from the GaN-on-GaN HB LED(s) is further aided by any mechanical attachment to the Heat Sink/Dissipation portion of the housing's surface. The Heat Sink/Dissipation portion(s) of the housing surface(s) would be designed with adequate surface area to allow adequate passive or dynamically forced thermal communication between the Illuminator housing, via the Fixture if required, and the environment to enable heat by way of thermal energy transfer to propagate from the GaN-on-GaN HB LED(s), through the Heat Sink/Dissipation portion(s) and/or housing and to the environment. At least one of the Heat Sink/Dissipation portion(s) will in a particular embodiment, comprise of a number of surfaces arranged in a way as to improve the thermal communication between the said surface(s) and the environment by increasing the 19 amount of surface area available. This particular arrangement of surfaces known as a Heat Sink is familiar to those skilled in the art. Typically the heat sink would normally be part of the overall construction of the Illuminator's housing. Apart from the shape and alignment of the ribs, fins or other structure(s) of the heat sink, a typical design should take into account the efficiencies of a static or passive heat sink design, as well as a design utilizing a forced thermal transfer between the housing and the environment. The thermal transfer efficiencies of such a design are well known to those skilled in the art of thermal management and LED lighting designs. A further design of this embodiment calls for the use of a forced air interaction with the Heat Sink Component of the Heat Dissipation Portion and the Illuminator housing. The forced air interaction may be passive in nature where the design of the Heat Sinking Element would become more practical when the Illuminator is mounted within a Fixture to take advantage of the moving air around it, or the Illuminator may be positioned stationary but utilize for example a fluid which is moving in a closed circuit, over and in contact with a surface(s) of the heat sink where the movement of fluid is from natural convection or another cause/effect. It is simply stated, that in our homes, Lighting Fixtures can be a personal choice. Many finishes are available and it is suffice to say, a design of the Illuminator's housing, may require a special treatment to suit a particular environment, use or trend. The Illuminator's housing, if required, due to the outputted thermal power of the GaN-on-GaN HB LED(s) used, may have a portion of its exterior surface coated in a substance so as to aid in its mechanical and environmental protection and not to significantly hinder heat convection/radiation from the heat dissipating portion of the housing. This protective layer(s) or substance may also act to enhance the aesthetic nature or appearance of the Illuminator as well as providing a corrosion inhibiting function(s) on any alloy that may be used in its construction. Other factors which may influence the surface treatments could be for example, fashion or trends, or be of a protective nature. This substance could be paint, an electrolytically applied coating/conversion, (for example Anodising in the case of an appropriate aluminium alloy), or any other applied finish(es). Where the housing of the Illuminator is 20 predominately a plastic (example UV stabilised Polycarbonate), the surfaces of the housing may have a smooth or textured feel and/or appearance to fit in with the overall Lighting Fixture's purpose, function, outward appearance or theme. When exposed to sunlight for example, a plastic may need to be stabilised against the affects of Ultra Violet (UV) radiation. Where the Illuminator is used on or near a waterway, especially a marine waterway, the materials used that are exposed to the environment should have a corrosion resistance property of at least a Marine Grade. The Inventors' wish to simply state that the illumination pattern or distribution from GaN-on-GaN HB LED(s) of the Illuminator, benefits from the use of a reflector or multiple reflectors and/or a lens or multiple lenses or combinations of reflectors and lenses, and simply stating that there is an infinite number of shapes and sizes and materials that could be designed into an Illuminator for reflectors and lenses for it's required light distribution pattern is understood by those knowledgeable in the art. More so, for example, the design and materials used should take into account any affect that environmental influences may have, as well as thermal management requirements if any, and light emission properties for the wavelengths emitted by the Illuminator. In the first preferred embodiment, the LED lamp PCB connects to an appropriately designed and constructed PCM PCB which is typically located in circuit between at least one power source suppling the Illuminator and at least one of the Illuminator's GaN-on-GaN HB LED(s) Die(s). In this case, the PCM could be designed to accept power from a directly connected power supply (eg: a 230/240vac supply in a typical Australian building, or be designed to accept a lower voltage, eg: a 24vdc system in a mobile home), and supplies by its design, the correct current form, voltage and/or current to power the GaN-on-GaN B LEDs Die(s) within the Illuminator. The PCM is typically mounted within the housings of the Illuminator, or mounted remotely from the Illuminator(s) but being able to still supply the correct power form to the Illuminator's LED(s) die(s). For example, a device may have more than one power supply source (such as a mains supply and a battery supply) and each source may have its own PCM attached. 21 In the second preferred embodiment the GaN-on-GaN HB LED(s) and PCM are electrically connected and encased in a housing, and has a cover to form the removably attached Illuminator. The Illuminator's power requirement would be reliant on its own PCM within the Illuminator to supply the correct regulated power by modifying the power form routed via the power supply to the Fixture. The PCM is so designed to take into account the voltage of the power supply to the Fixture and has an appropriately designed circuit to be compatible with, for example, an existing wall mounted dimming Triac that was used to control the prior art lamp/illuminato The thermal designs of this Illuminator would take into account the heat generated by the Illuminator, particularly the heat generated at the base of the GaN-on-GaN HB LED(s) and also that of the PCM. In yet another embodiment, the GaN-on-GaN HB LED Faultless High Efficiency Illuminator which may not have it's own PCM within it's housing but may utilize an adaptor to draw the preferred power from an early art Fixture's lamp socket. The PCM may be of the form of an "adaptor", to interface between and utilize the power supply voltages and forms of an early art Illuminator Fixture and power supply and to modify the power form to suit a GaN-on-GaN HB LED model Illuminator which would normally be unable to connect to the said Fixture's pre-existing prior art socket. An example of "new art Illuminator into prior art Fixture Adaptor" is where the secondary side socket of an adaptor accepts a connection from an appropriately designed new art GaN-on-GaN HB LED Illuminator into the adaptor's socket. At the other end, the primary input power side, the BC type plug allows the adaptor to connect to a prior art pre-existing Lamp socket (or primary socket) (in this case a BC socket to match the BC Cap). The middle section of the adaptor, would house the PCM that would modify the input power supply from the prior art compatible plug connector to a form that matches the requirement of the new art GaN-on-GaN HB LED Illuminator that is attached to the secondary socket connector at. A particularly important requirement of the total design of the "Adaptor" would become very obvious. That is to say, the connecting plug of a new art Illuminator that connects to would need to be alien or non-compatible both in any physical attribute as well as and more importantly electrically un-mateable to a pre-existing prior art socket of a Lighting Fixture that the adaptor's plug connects to. This incompatibility between 22 primary and secondary plugs and sockets is a must, mostly for safety reasons. For example, a low voltage Illuminator would most likely be damaged in the least, if connected directly to a high voltage pre-existing prior art socket of a prior art Lighting Fixture. The adaptor must satisfy safety design requirements of the appropriate jurisdiction that they are used in. Simply put, the new art Illuminator base that connects to the socket connector would be unique so as not to match the socket of any other prior art Fixture's Illuminator socket and designed so the Illuminator's input power connector of the GaN-on-GaN HB LED Illuminator cannot be attached to the early art pre-existing socket directly, either electrically and/or physically. In another design, the Faultless High Efficiency Illuminator may be constructed so as to include a PCM, and the Illuminator having a unique input power plug could mate to an adaptor that does not include a PCM. The adaptor is to purely allow a prior art Fixture socket to supply power to a new art Illuminator plug. The combined use of the adaptor and the new Illuminator allows one solution to replace an early art lamp with new technology. The adaptor may be sold separately to the Illuminator for the benefit to a consumer or together with the Illuminator as a "kit". A prior art Lighting Fixture may be "upgraded" using a special retrofit Illuminator system with separately attached PCM and Lamp. For example, with an integrated or attached module housing containing a PCM, a new art Illuminator and separately attached PCM is connected to an early art Fixture's pre-existing BC Socket via the BC cap plug enabling a new art Illuminator to fit to a prior art Fixture. The lowest level/amount of power (form, voltage and current) required to illuminate an LED Die to an effective illumination level must also be of a level so as not to cause premature deterioration or failure of the LED's die. An LED Die can deteriorate considerably and have a greatly reduced lifetime when "driven" at too low a power, as well as too high a power. A minimum level at where the LED Die will not be greatly adversely affected is defined. This level of illumination is referred to as the "minimum effective threshold of illumination" for any given LED Die. The LED Die also has a maximum effective threshold which relates to the amount of illumination 23 produced from the maximum level of safe power (form, voltage and current) that an LED Die is designed to use before there is premature deterioration or failure. The range of power between these two limits is defined herein as the "effective operating power range" (eopr) of the LED Die. Without limiting the design, it is simply stated that the PCM, may for example, be at least a group(s) of electronic component(s) mounted to a PCB(s) and acting as a constant current delivering module (eg: Buck, boost, buck-boost, SEPIC, etc), or it may be at least a single component acting as a power regulator (such as a simple linear current device). The Illuminator's LED(s) would utilise the eopr power form from an appropriately designed power supply either directly or via a power control/management module which has the ability to modify the power requirements of the Illuminator should it be required, eg: a remote controlled power controller. In the examples mentioned above, the Illuminator is predominately "removably fitted" to the Fixture or device. That is to say, the Illuminator may be easily replaced at end of life or as required. Most prior art Lighting Fixtures used in our homes and buildings, usually utilize "mains" voltage power as a power source (230/240v ac in Australia). An example is a structure where the requirement of an Illuminator using GaN-on-GaN HB LED technology would need to be able to work when installed in unison with a prior art Fixture element, and could be electrically controlled by a standard "triac" style dimmer control. The PCM in this example, would modify the power input from the mains voltage ac power source directly or via a step-down transformer or ballast, and supplies the modified output so as to be a constant current power source which is required for the GaN-on-GaN HB LED(s) of this example. One example of a PCM to do this would be an electronic PCB utilizing a Texas Instruments' LM3445 triac dimmable offline LED driver solution. The LM3445 LED driver with an Faultless High Efficiency Illuminator enables a direct replacement of incandescent or halogen lamp Illuminator that is currently interfaced to a TRIAC dimmer without having to change the original infrastructure or sacrifice performance. 24 In some sensitive or mission critical designs, appropriate levels of regulation of non conforming power supply may be required in addition to the normal design of a PCM. Eg: to guard against power surges and Electro-magnetic pulses (EMP), lightning strikes, electro-static discharge (ESD) and other causes. A compulsory requirement in Australia for most electrical items as well as the Invention, is a need to satisfy Australian Communications and Media Authority (ACMA) Electro Magnetic Compatibility requirements (EMC). Satisfying these requirements also requires marking the equipment with the appropriate symbol, in this case the "RCM" mark. The RCM mark replaces the C-tick and A-tick and RCM marks in Australia from March 1 s 2013 with some transitional arrangements. Placement of the GaN-on-GaN HB LED(s) PCM is important as it may generate its own heat and this thermal mass must, like the GaN-on-GaN HB LED's operating thermal mass, be controlled, attenuated or managed and/or be kept within recommended limits. Referring back to the first preferred embodiment, attaching the PCM (in part or as a whole) to a surface of the Illuminator's housing (or bonding of the PCM to the Illuminator's Housing usually suffices. The PCM in its particular form, may be an inclusion in the Illuminator's design, or the PCM may be separate from the Illuminator but still be enclosed in another element or module of the Fixture, or the PCM may be separate altogether or remote from the Fixture itself. One example is a PCM that is able to supply the correct required power form to two or more Fixtures' Illuminator(s). However, in most cases, the PCM is usually placed in circuit between the primary power supply and at least one of the GaN-on-GaN HB LED(s). It is generally considered that the GaN-on-GaN HB LED(s) has/have a requirement for a PCM to supply the required power form but not necessarily be placed or fixed in any particular fixed location or position relative to the GaN-on-GaN HB LED(s) and that the requirement is that the PCM is placed at least, somewhere in circuit between the power supply and at least one of the GaN-on-GaN HB LED(s) of the Illuminator. 25 It is a preferred requirement that there be a means to sense the temperature(s) of the PCM, and the GaN-on-GaN HB LED(s). The usual methods, acknowledged by those skilled in the art, are to use either thermistors, and/or analogue (or digital) Integrated Circuit (IC) sensors. These operate by maintaining an appropriate "feedback" to the PCM of the temperatures at the placement zones of the Illuminator's components, and so allow the PCM, in it's design, should it be required, to moderate the output current load to the GaN-on-GaN HB LED(s) to reduce the power load of the system and so in turn, bring the operating temperature(s) down to a safe level. This works to ensure that the GaN-on-GaN HB LED(s) does not have a shortened life expectancy, and parts of, or parts adjacent to, the Faultless High Efficiency Illuminator are not thermally damaged. The GaN-on-GaN HB LED(s) of the Invention is not limited to producing light output of a Whitish colour. A white LED for example may be considered a warm white (eg: slightly yellowish and approximately 2600-3500 degrees Kelvin), neutral white (eg: mostly white and approximately 3500-5000 degrees Kelvin), or cool white (eg: slightly bluish and over approximately 5000 degrees Kelvin) approximately, depending on their respective colour temperatures measured in degrees Kelvin. For example, a requirement for light of a different colour/wavelength (eg: often a reddish tint) is sometimes used in a place where animals gather at night. Visible lighting for artistic appreciation may be of a colour other than white and is commonly used in museums and art galleries. Usually however, indoor lighting is of a whitish colour. Visible light (for humans) ranges in wavelength from about 390 nanometres (nm) for deep blue/violet light up to about 900 nm for red light approaching infrared). For example, to obtain a colour tinted light output, a white output Illuminator could be used behind a colour-tinted cover, or a colour output LED may be positioned behind a clear cover, or other combinations. One further example is of the use of a specific coating/tint to enhance or attenuate certain wavelength(s) of the light emitted and may also include reflectors and lenses or covers or for example a wavelength changing or modifying cover(s). In some "Museum" displays, certain wavelengths of light may enhance a display or may cause deterioration. 26 However, colour output lights, unless for a specific illumination need, (eg: a nocturnal animal feeding site as mentioned), are mostly limited to Conspicuity lighting, Spotlighting, or signalling and are not referred to as being included in the Invention herein described. A further feature is the ability to modify the light output strength, as full brightness may sometimes be too illuminating. This would mostly and preferably be performed by modifying the current to the GaN-on-GaN HB LED(s), and in most cases this is usually accomplished by Pulse Width Modulation (PWM) of the LED's PCM's output to the GaN-on-GaN HB LED(s). The controlling nature of a PCM, and the Illuminator(s) that it delivers power to, may be further enhanced by the use of remote control with the aid of for example, wireless technologies and other remote control devices utilising different data transmission protocols and techniques. Eg: Wi-Fi, Bluetooth, Zigbee, Canbus, Radio Frequency (RF), modulated light (eg: infrared or IR), wired networks means and others. Sound waves could also be used. Eg: when we clap our hands, certain audio receivers can be constructed to control the dimming of lights in a room. The disclosed description of the Invention reveals the advantages and methods of how to produce a reliable, Faultless GaN-on-GaN HB LED(s) Faultless High Efficiency Illuminator. The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the Inventors to make use of the Invention. Nothing in this specification should be considered as limiting the scope of the present Invention. All examples presented are representative and non-limiting. The above-described embodiments of the Invention may be modified or varied, without departing from the Invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the Invention may be practiced otherwise than as specifically described. 27
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