Laminated LED array and/or products including the same
View Patent ↗In certain example embodiments, light emitting diodes (LEDs) may be disposed on a deformable and flexible backbone sheet and chained together in an array, e.g., via flexible wiggle wires. Such flexible wiggle wires may also provide an electrical connection to an external power source. An optical out-coupling layer stack (OCLS) system may help serve as an index matching layer, heat sink, étendue conserver, etc. The backbone may be formed to a shape tailored to its ultimate application. Applications may include, for example, automotive (such as Center High Mounted Stop Lamp (CHMSL) applications), lighting, signage, and/or other applications. In an example CHMSL application, the deformable sheet with the LED array thereon has a step, sinusoidal, or other shape matched to the angle and/or curvature of the glass such that the LEDs produce light primarily in a direction parallel to a surface on which a vehicle is located.
1. A rear windshield for a vehicle, comprising
first and second glass substrates, laminated to one another via a first laminating material to form the rear windshield; and a center high mounted stop lamp in the rear windshield for the vehicle that includes:
a deformable non-conductive backbone substrate supporting a plurality of LED devices of the rear windshield, the deformable backbone being disposed between the first and second substrates of the rear windshield, the LED devices being connected to one another via flexible wires,
wherein the backbone substrate has a shape so that the LED devices, when powered, emit light primarily in a direction parallel to a surface on which the vehicle is located so as to function as a stop lamp for the vehicle, the direction in which the LED devices primarily emit light also being non-perpendicular to an outer surface of the rear windshield,
wherein the backbone substrate is shaped so as to have a plurality of steps, each said step supporting at least one of said LEDs and being non-perpendicular and non-parallel to the outer surface of the rear windshield, and the deformable non-conductive backbone substrate is a flexible sheet that has a substantially sinusoidal shape.
2. The rear windshield of claim 1 , wherein the first laminating material comprises PVB.
3. The rear windshield of claim 1 , wherein the backbone substrate is formed from PET, polyimide, polyamide, and/or PMMA.
4. The rear windshield of claim 1 , further comprising an optical out-coupling layer stack (OCLS) system, the OCLS system comprising an isotropic layer matrix including an organo-metallic chelate hybrid material and a matrix core including dispersed scatterers.
5. The rear windshield of claim 4 , wherein the dispersed scatterers have a Mie-like scattering efficiency of greater than 1, leading to an index matching out-coupling efficiency for the OCLS of greater than 1, and wherein the OCLS system is provided over the LEDs.
6. The rear windshield of claim 4 , wherein the layer matrix includes a polymeric monomer to which oxo-clusters are added.
7. The rear windshield of claim 6 , wherein the oxo-clusters include Ti, Hf, and/or Zr oxo-clusters.
8. The rear windshield of claim 4 , wherein a filling density of the scatterers is in a range of values such that the scatterers are mono-dispersed with an inter-particle distance d of about 3 diameters or major distances.
9. The rear windshield of claim 8 , wherein each scatterer is located in a far field of its nearest neighbor and there is no systematic phase relationship, except for coherent exact forward scattering.
10. The rear windshield of claim 4 , further comprising a second laminating material encapsulating the backbone substrate.
11. The rear windshield of claim 1 , further comprising a low-emissivity (low-E) coating disposed on the first and/or second substrate.
12. The rear windshield of claim 11 , wherein:
the LED devices are chained together to form an array;
at least some leads extend from the array and are in direct electrical contact with the low-E coating; and
the LED devices are addressable and/or powerable via the low-E coating.
13. The rear windshield of claim 1 , wherein the LED devices are chained together to form an array that operates at a temperature of no greater than 150 degrees C.
14. A rear windshield for a vehicle, comprising
first and second glass substrates, laminated to one another via a first laminating material to form the rear windshield; and a center high mounted stop lamp in the rear windshield for the vehicle that includes:
a deformable non-conductive backbone substrate supporting a plurality of LED devices of the rear windshield, the deformable backbone being disposed between the first and second substrates of the rear windshield, the LED devices being connected to one another via flexible wires,
wherein the backbone substrate has a shape so that the LED devices, when powered, emit light primarily in a direction parallel to a surface on which the vehicle is located so as to function as a stop lamp for the vehicle, the direction in which the LED devices primarily emit light also being non-perpendicular to an outer surface of the rear windshield,
wherein the backbone substrate is shaped so as to have a plurality of steps, each said step supporting at least one of said LEDs and being non-perpendicular and non-parallel to the outer surface of the rear windshield.