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 support substrate including a thermally conductive material;
an LED emitter sheet overlying the support substrate, the LED emitter sheet including a plurality of LED light emitters;
a flexible circuit sheet overlying the LED emitter 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 LED emitter sheet comprises a ceramic substrate with 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 LED emitter sheet comprises separate LED emitters.
8. 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.
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, an LED emitter sheet, and a support substrate sheet, wherein:
the support substrate sheet includes a thermally conductive material;
the LED emitter 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 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 LED emitter sheet comprises a ceramic substrate sheet with 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.
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 the 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.
20. 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, and an LED emitter sheet, wherein:
the LED emitter 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 lenses.
21. The flexible sheet of LED light emitters of claim 20 , further comprising a support substrate sheet.
22. The flexible sheet of LED light emitters of claim 21 , wherein the support substrate sheet comprises a thermally conductive material.
23. The flexible sheet of LED light emitters of claim 21 , wherein the support substrate sheet is disposed under the LED emitter sheet.