Flexible lighting device having unobtrusive conductive layers

• US 9,214,614 B2
• Filed: 07/23/2013
• Issued: 12/15/2015
• Est. Priority Date: 07/23/2013
• Status: Active Grant

• Current Assignee: Grote Industries LLC (Grote Industries Incorporated)
• Original Assignee: Grote Industries LLC (Grote Industries Incorporated)
• Inventors: Jones, Scott J., Marx, Martin J., Robbins, Stanley D., Roberts, James E.
• Primary Examiner(s): Ahmad, Khaja
• Application Number:
  US13/948,472
• Publication Number:
  US 20150028377A1
• Time in Patent Office: 875 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: H01L 2224/13 of an individual bump connector
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 33/62 Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls

Abstract

A lighting element is provided, comprising: a substrate; a first conductive element on the substrate; a light-emitting element having first and second contacts on top and bottom surfaces, respectively; a transparent layer adjacent to the top surface; an affixing layer between the substrate and the transparent layer, affixing the transparent layer to the substrate; and a second conductive element beneath the transparent layer and proximate to the top surface, wherein the first and second contacts are electrically connected to the first and second conductive elements, respectively, the light-emitting element emits light in a range of wavelengths between 10 nm and 100,000 nm, the transparent and affixing layer'"'"'s will not decrease light transmittance below 70%, and the first and second conductive elements are at least partially transparent to visible light, or are 300 μm or smaller in width, or are concealed by a design feature from a viewing direction.

Claims

1. A lighting element, comprising:

a first flexible substrate;

a first conductive element located on the first flexible substrate;

a light-emitting element having a first contact and a second contact, the first contact being on a first surface of the light-emitting element, the second contact being on a second surface of the light-emitting element that is opposite to the first side;

a flexible transparent layer located adjacent to the second surface of the light-emitting element;

a transparent affixing layer located between the first flexible substrate and the flexible transparent layer, the affixing layer being configured to affix the flexible transparent layer to the first flexible substrate; and

a second conductive element located beneath the flexible transparent layer and proximate to the second surface of the light-emitting element,

wherein

the first contact is electrically connected to the first conductive element,

the second contact is electrically connected to the second conductive element,

the light-emitting element is configured to emit light from the second surface with the light having wavelengths between 10 nm and 100,000 nm,

the flexible transparent layer and the transparent affixing layer are both sufficiently transparent to visible light such that they will not decrease light transmittance below 70%, and

the first and second conductive elements are at least partially transparent to visible light.

2. The lighting element of claim 1, further comprising:

a second transparent conductive layer formed at least partially adjacent to the second contact and at least partially adjacent to the second conductive element, the second transparent conductive layer configured to electrically connect the second contact and the second conductive element,

wherein the second transparent conductive layer is sufficiently transparent to visible light such that they will not decrease light transmittance below 70%.

3. The lighting element of claim 2, further comprising:

a first transparent conductive layer formed at least partially adjacent to the first contact and at least partially adjacent to the first conductive element, the first transparent conductive layer configured to electrically connect the first contact and the first conductive element,

wherein the first transparent conductive layer is sufficiently transparent to visible light such that they will not decrease light transmittance below 70%.

4. The lighting element of claim 2, wherein

the light-emitting element is formed to be at least partially over the first conductive element.

5. The lighting element of claim 3, wherein

no part of the light-emitting element is formed over the first conductive element.

6. The lighting element of claim 2, further comprising:

a third conductive element located on the first flexible substrate;

a connection element located between the second conductive element and the third conductive element, the connection element being configured to electrically connect the second conductive element to the third conductive element,

wherein the third conductive element is at least partially transparent to a selected wavelength of light.

7. The lighting element of claim 6, wherein

the connection element is at least partially transparent to the selected wavelength of light.

8. The lighting element of claim 1, wherein

the flexible transparent layer is one of a second flexible substrate and a flexible hardened conformal coating.

9. The lighting element of claim 1, wherein

the first flexible substrate is substantially transparent to the selected wavelength of light.

10. The lighting element of claim 1, wherein

the first and second conductive elements each comprise copper, copper alloy silver, silver alloy aluminum, or aluminum alloy.

11. The lighting element of claim 1, wherein

the first and second conductive elements are both buss bars.

12. A lighting element, comprising:

a first substrate;

a first conductive element located on the first substrate;

a light-emitting element having a first contact and a second contact, the first contact being on a first surface of the light-emitting diode, the second contact being on a second surface of the light-emitting element that is opposite to the first side;

a transparent layer located adjacent to the second surface of the light-emitting element;

a transparent affixing layer located between the first substrate and the transparent layer, the transparent affixing layer being configured to affix the transparent layer to the first substrate; and

a second conductive element located beneath the transparent layer and proximate to the second surface of the light-emitting element,

wherein

the first contact is electrically connected to the first conductive element,

the second contact is electrically connected to the second conductive element,

the light-emitting element is configured to emit light from the second surface with the light in wavelengths between 10 nm and 100,000 nm,

the transparent layer and the transparent affixing layer are both sufficiently transparent to visible light such that they will not decrease light transmittance below 70%,

the first and second conductive elements are 300 μ

m or smaller in width, the width being measured in a direction parallel to a top surface of the first substrate,

the first substrate is a flexible substrate, and

the transparent layer is a flexible transparent layer.

13. The lighting element of claim 12, further comprising:

a second transparent conductive layer formed at least partially adjacent to the second contact and at least partially adjacent to the second conductive element, the second transparent conductive layer configured to electrically connect the second contact and the second conductive element,

wherein the second transparent conductive layer is sufficiently transparent to visible light such that they will not decrease light transmittance below 70%.

14. The lighting element of claim 13, further comprising:

a first transparent conductive layer formed at least partially adjacent to the first contact and at least partially adjacent to the first conductive element, the first transparent conductive layer configured to electrically connect the first contact and the first conductive element,

wherein the first transparent conductive layer is sufficiently transparent to visible light such that they will not decrease light transmittance below 70%.

15. The lighting element of claim 14, wherein

the light-emitting element is applied to be at least partially over the first conductive element.

16. The lighting element of claim 14, wherein

no part of the light-emitting element is applied over the first conductive element.

17. The lighting element of claim 13, further comprising:

a third conductive element located on the first substrate;

a connection element located between the second conductive element and the third conductive element, the connection element being configured to electrically connect the second conductive element to the third conductive element,

wherein the third conductive element is at least partially transparent to selected wavelengths between 10 nm and 100,000 nm.

18. The lighting element of claim 12, wherein the connection element is at least partially transparent to a wavelength of light between 10 nm and 100,000 nm.

19. The lighting element of claim 12, wherein

the transparent layer is one of a second substrate and a hardened conformal coating.

20. The lighting element of claim 12, wherein

the first and second conductive elements each comprise a conductive material.

21. The lighting element of claim 12, wherein

the first and second conductive elements each comprise copper, copper alloy, silver, silver alloy, aluminum, or aluminum alloy, conductive epoxy, or conductive inks.

22. The lighting element of claim 12, wherein

the first and second conductive elements are both buss bars.

23. A lighting element, comprising:

a first substrate;

a first conductive element located on the first substrate;

a light-emitting element having a first contact and a second contact, the first contact being on a first surface of the light-emitting element, the second contact being on a second surface of the light-emitting element that is opposite to the first side;

a transparent layer located adjacent to the second surface of the light-emitting element;

a transparent affixing layer located between the first substrate and the transparent layer, the transparent affixing layer being configured to affix the transparent layer to the first substrate;

a second conductive element located beneath the transparent layer and proximate to the second surface of the light-emitting element; and

an opaque design feature formed over at least one of the first conductive element and the second conductive element, the opaque design concealing at least one of the first conductive element and the second conductive element from above,

wherein

the first contact is electrically connected to the first conductive element,

the second contact is electrically connected to the second conductive element,

the light-emitting element is configured to emit light from the second surface with the light having wavelengths between 10 nm and 100,000 nm,

the transparent layer and the transparent affixing layer are both sufficiently transparent to visible light such that they will not decrease light transmittance below 70%,

the first substrate is a flexible substrate, and

the transparent layer is a flexible transparent layer.

24. The lighting element of claim 23, further comprising:

a second transparent conductive layer applied at least partially adjacent to the second contact and at least partially adjacent to the second conductive element, the second transparent conductive layer configured to electrically connect the second contact and the second conductive element,

wherein the second transparent conductive layer is sufficiently transparent to visible light such that they will not decrease light transmittance below 70%.

25. The lighting element of claim 24, further comprising:

a first transparent conductive layer formed at least partially adjacent to the first contact and at least partially adjacent to the first conductive element, the first transparent conductive layer configured to electrically connect the first contact and the first conductive element,

wherein the first transparent conductive layer is sufficiently transparent to visible light such that they will not decrease light transmittance below 70%.

26. The lighting element of claim 25, wherein

the light-emitting element is formed to be at least partially over the first conductive element.

27. The lighting element of claim 25, wherein

no part of the light-emitting element is formed over the first conductive element.

28. The lighting element of claim 24, further comprising:

a third conductive element located on the first substrate;

a connection element located between the second conductive element and the third conductive element, the connection element being configured to electrically connect the second conductive element to the third conductive element,

wherein the third conductive element is at least partially transparent to wavelengths between 10 nm and 100,000 nm.

29. The lighting element of claim 28, wherein the connection element is at least partially transparent to the wavelengths between 10 nm and 100,000 nm.

30. The lighting element of claim 23, wherein

the transparent layer is one of a second substrate and a hardened conformal coating.

31. The lighting element of claim 23, wherein the opaque design feature comprises:

a first opaque design feature formed over the first conductive element, the first opaque design completely concealing the first conductive element from above; and

a second opaque design feature formed over the second conductive element, the second opaque design completely concealing the second conductive element from above.

32. The lighting element of claim 23, wherein

the first and second conductive elements are both buss bars.

33. The lighting element of claim 23, wherein the opaque design feature is an ornamental decoration, a frame, a filter, or a mask.