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Flexible light engine with bus bars and interconnectors

  • US 10,132,453 B2
  • Filed: 08/23/2016
  • Issued: 11/20/2018
  • Est. Priority Date: 08/23/2016
  • Status: Active Grant
First Claim
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1. A method of roll-to-roll manufacturing a circuit for a flexible light engine (10), comprising:

  • providing an electrically insulating, flexible lower laminate sheet (12) from a first roll;

    providing an electrically insulating, flexible upper laminate sheet (14) from a second roll;

    forming electrically conductive first and second metallic bus bars (20, 22) in a single conductive layer on at least one of the lower and upper laminate sheets (12, 14);

    forming electrically conductive interconnectors (30) at a plurality of locations on each of the first and second metallic bus bars (20, 22);

    providing a metallic strip (40) from a third roll;

    disposing the metallic strip (40) in the single conductive layer on at least one of the lower and upper laminate sheets (12, 14);

    connecting the metallic strip (40) via the interconnectors (30) to the first metallic bus bar (20) at the plurality of interconnector locations of the first metallic bus bar (20);

    connecting the metallic strip (40) via the interconnectors (30) to the second metallic bus bar (22) at the plurality of electrical interconnector locations of the second metallic bus bar (22);

    retaining the metallic strip (40) between the lower laminate sheet (12) and the upper laminate sheet (14) by laminating the lower laminate sheet (12) with the upper laminate sheet (14), whereby the laminating also disposes the first and second metallic bus bars (20, 22) between the lower laminate sheet (12) and the upper laminate sheet (14);

    perforating the upper laminate sheet (14), wherein perforations (16) of the upper laminate sheet (14) are in register with exposed portions (42) of the metallic strip (40);

    perforating the exposed portions (42) of the metallic strip (40) thereby defining a plurality of metallic contacts (50);

    coupling an LED package (60) within each perforation (16) of the upper laminate sheet (14) to the metallic contacts (50) provided by the exposed portions (42) of the metallic strip (40), thereby defining a plurality of series LED strings (64) connected in parallel between the first and second metallic bus bars (20, 22); and

    coiling the flexible light engine (10) onto a fourth roll.

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