Method and system for forming LED light emitters
A flexible sheet of light-emitting diode (LED) light emitters includes a support substrate having a thermally conductive material. The flexible sheet of LED light emitters also has an LED emitter sheet overlying the support substrate, and the LED emitter sheet including a plurality of LED light emitters. The flexible sheet of LED light emitters also has a flexible circuit sheet overlying the LED emitter sheet, and a phosphor sheet overlying the flexible circuit sheet. The phosphor sheet includes a wave-length converting material. The flexible sheet of LED light emitters also has a lens sheet overlying the phosphor sheet. The lens sheet includes a plurality of lenses.
1. A flexible sheet of light-emitting diode (LED) light emitters, comprising:
a flexible support substrate including a thermally conductive material;
a plurality of LED light emitters overlying the flexible support substrate;
a flexible circuit sheet coupled to the plurality of LED light emitters;
a phosphor layer overlying the plurality of LED light emitters, the phosphor layer including a wave-length converting material; and
a plurality of lenses overlying the phosphor layer.
2. The flexible sheet of LED light emitters of claim 1 , wherein each of the plurality of LED light emitters comprises multiple LED dies.
3. The flexible sheet of LED light emitters of claim 1 , wherein the flexible sheet of LED emitters is also stretchable.
4. The flexible sheet of LED light emitters of claim 1 , wherein the phosphor layer comprises a plurality of phosphor regions, each of the phosphor regions is aligned to a corresponding one of the plurality of LED light emitters.
5. The flexible sheet of LED light emitters of claim 1 , wherein each of the plurality of lenses is aligned to a corresponding one of the plurality of LED light emitters.
6. The flexible sheet of LED light emitters of claim 1 , wherein the plurality of lenses are singulated from a lens sheet comprising pre-formed notches between adjacent lenses.
7. The flexible sheet of LED light emitters of claim 6 , wherein the lens sheet comprises separate lenses.
8. The flexible sheet of LED light emitters of claim 1 , wherein the plurality of LED light emitters are singulated from an LED emitter sheet comprising a ceramic substrate with pre-formed notches between adjacent emitters.
9. The flexible sheet of LED light emitters of claim 1 , wherein the plurality of LED light emitters comprises separate LED emitters.
10. The flexible sheet of LED light emitters of claim 1 , wherein the plurality of LED light emitters are inorganic solid-state based LED light sources.
11. A flexible sheet of light-emitting diode (LED) light emitters, comprising a flexible support substrate, a flexible circuit layer, a flexible phosphor layer, a plurality of LED light emitters, and a plurality of lenses, wherein:
the flexible support substrate includes a thermally conductive material;
the flexible circuit layer includes conductive wires;
the plurality LED light emitters overlies the flexible support substrate;
the plurality LED light emitters are electrically coupled to the flexible circuit layer;
the flexible phosphor layer overlies the plurality LED light emitters; and
the plurality of lenses overlies the plurality LED light emitters.
12. The flexible sheet of LED light emitters of claim 11 , wherein each of the plurality of LED light emitters comprises multiple LED dies.
13. The flexible sheet of LED light emitters of claim 11 , wherein each of the plurality of lenses is aligned to a corresponding one of the plurality of LED light emitters.
14. The flexible sheet of LED light emitters of claim 11 , wherein the plurality of lenses are singulated from a lens sheet comprising pre-formed notches between adjacent lenses.
15. The flexible sheet of LED light emitters of claim 11 , wherein the plurality of LED light emitters are singulated from an LED emitter sheet comprising a ceramic substrate sheet with pre-formed notches between adjacent emitters.
16. The flexible sheet of LED light emitters of claim 11 , wherein the flexible sheet of LED light emitters is also stretchable.
17. The flexible sheet of LED light emitters of claim 11 , wherein the flexible circuit layer is also stretchable.
18. The flexible sheet of LED light emitters of claim 17 , wherein the flexible circuit layer comprises conductive wires that are in zig-zag form.
19. The flexible sheet of LED light emitters of claim 11 , wherein the plurality of LED light emitters are inorganic solid-state based LED light sources.
20. The flexible sheet of LED light emitters of claim 11 , wherein the flexible circuit layer is disposed under the plurality of LED light emitters.
21. The flexible sheet of LED light emitters of claim 11 , wherein the flexible circuit layer is disposed over the plurality of LED light emitters.
22. The flexible sheet of LED light emitters of claim 11 , wherein the flexible circuit layer is disposed under the plurality of LED light emitters, and a second flexible circuit layer is disposed over the plurality of LED light emitters.
23. A flexible sheet of light-emitting diode (LED) light emitters, comprising:
a flexible circuit sheet, the flexible circuit sheet including conductive wires;
a plurality of LED light emitters electrically coupled to the flexible circuit sheet;
a phosphor material overlying each of the plurality of LED light emitters, the phosphor material including a wave-length converting material; and
a plurality of lenses, wherein each of the plurality of lenses is aligned to a corresponding one of the plurality of LED light emitters.
24. The flexible sheet of LED light emitters of claim 23 , wherein each of the plurality of LED light emitters comprises multiple LED dies.
25. The flexible sheet of LED light emitters of claim 23 , further comprising a flexible support substrate.
26. The flexible sheet of LED light emitters of claim 25 , wherein the flexible support substrate comprises a thermally conductive material.
27. The flexible sheet of LED light emitters of claim 25 , wherein the flexible support substrate is disposed under the flexible sheet of LED light emitters.