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 a ceramic substrate sheet overlying the support substrate, and the ceramic substrate sheet including a plurality of LED light emitters. The flexible sheet of LED light emitters also has a flexible circuit sheet overlying the ceramic substrate 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 support substrate including a thermally conductive material;
a ceramic substrate sheet overlying support substrate, the ceramic substrate sheet including a plurality of LED light emitters;
a flexible circuit sheet overlying the ceramic substrate sheet;
a phosphor sheet overlying flexible circuit sheet, the phosphor sheet including a wave-length converting material; and
a lens sheet overlying the phosphor sheet, the lens sheet including a plurality of lenses.
2. The flexible sheet of LED light emitters of claim 1 , wherein the flexible sheet of LED emitters is also stretchable.
3. The flexible sheet of LED light emitters of claim 1 , wherein each of the plurality of lenses in the lens sheet is aligned to a corresponding one of the plurality of LED light emitters.
4. The flexible sheet of LED light emitters of claim 1 , wherein the lens sheet comprises pre-formed notches between adjacent lenses.
5. The flexible sheet of LED light emitters of claim 1 , wherein the ceramic substrate comprises pre-formed notches between adjacent emitters.
6. The flexible sheet of LED light emitters of claim 1 , wherein the lens sheet comprises separate lenses.
7. The flexible sheet of LED light emitters of claim 1 , wherein the ceramic substrate comprises separate LED emitters.
8. The flexible sheet of LED light emitters of claim 1 , wherein a plurality of LED light emitters are inorganic solid-state based LED light sources.
9. A flexible sheet of light-emitting diode (LED) light emitters, comprising a stack of sheets including a lens sheet, a phosphor sheet, a flexible circuit sheet, a ceramic substrate sheet, and a support substrate, wherein:
the support substrate includes a thermally conductive material;
the ceramic substrate sheet includes a plurality of LED light emitters;
the flexible circuit sheet includes conductive wires;
the phosphor sheet includes a wave-length converting material; and
the lens sheet includes a plurality of micro lenses.
10. The flexible sheet of LED light emitters of claim 9 , wherein each of the plurality of lenses in the lens sheet is aligned to a corresponding one of the plurality of LED light emitters.
11. The flexible sheet of LED light emitters of claim 9 , wherein the lens sheet comprises pre-formed notches between adjacent lenses.
12. The flexible sheet of LED light emitters of claim 9 , wherein the ceramic substrate comprises pre-formed notches between adjacent emitters.
13. The flexible sheet of LED light emitters of claim 9 , wherein the flexible sheet of LED light emitters is also stretchable.
14. The flexible sheet of LED light emitters of claim 9 , wherein the flexible circuit sheet is also stretchable and the conductive wires are in zig-zag form.
15. The flexible sheet of LED light emitters of claim 14 , wherein the flexible circuit sheet comprises conductive wires that are in zig-zag form.
16. The flexible sheet of LED light emitters of claim 9 , wherein a plurality of LED light emitters are inorganic solid-state based LED light sources.
17. The flexible sheet of LED light emitters of claim 9 , wherein the flexible circuit sheet is disposed under the plurality of LED light emitters.
18. The flexible sheet of LED light emitters of claim 9 , wherein the flexible circuit sheet is disposed over the plurality of LED light emitters.
19. The flexible sheet of LED light emitters of claim 9 , wherein the flexible circuit sheet is disposed under the plurality of LED light emitters, and a second flexible circuit sheet is disposed over the plurality of LED light emitters.