Wiring boards for array-based electronic devices

• US 9,526,132 B2
• Filed: 09/29/2014
• Issued: 12/20/2016
• Est. Priority Date: 09/06/2012
• Status: Active Grant

• Current Assignee: Cooledge Lighting Inc.
• Original Assignee: Cooledge Lighting Inc.
• Inventors: Palfreyman, Paul, Tischler, Michael A., Schick, Philippe M., Jungwirth, Paul
• Primary Examiner(s): Coughlin, Andrew
• Assistant Examiner(s): ULANDAY, MEGHAN K
• Application Number:
  US14/499,887
• Publication Number:
  US 20150077991A1
• Time in Patent Office: 813 Days
• Field of Search: 315/185.R
• US Class Current: 1/1
• CPC Class Codes: F21S 2/00 Systems of lighting devices, not provided for in main groups F21S4/00 - F21S10/00 or F21S19/00, e.g. of modular construction
• CPC Class Codes: F21S 4/22 flexible or deformable, e.g. into a curved shape
• CPC Class Codes: F21V 21/005 for several lighting devices in an end-to-end arrangement, i.e. light tracks
• CPC Class Codes: F21V 21/14 Adjustable mountings
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 23/02 the elements being transformers, impedances or power supply units, e.g. a transformer with a rectifier
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2105/12 characterised by the geometrical disposition of the light-generating elements, e.g. arranging light-generating elements in differing patterns or densities
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/16225 the item being non-metallic, e.g. insulating substrate with or without metallisation
• CPC Class Codes: H01L 2224/32225 the item being non-metallic, e.g. insulating substrate with or without metallisation
• CPC Class Codes: H01L 2224/73204 the bump connector being embedded into the layer connector
• CPC Class Codes: H01L 2224/92125 the second connecting process involving a layer connector
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H05B 45/10 Controlling the intensity of the light
• CPC Class Codes: H05B 45/40 Details of LED load circuits
• CPC Class Codes: H05B 45/44 with an active control inside an LED matrix
• CPC Class Codes: H05B 45/46 having LEDs disposed in parallel lines
• CPC Class Codes: H05K 1/00 Printed circuits

Abstract

In accordance with certain embodiments, lighting systems include one or more lightsheets each including a plurality of strings of light-emitting elements, control elements, and power conductors for supplying power to the light-emitting elements and control elements.

Claims

1. A lighting system comprising:

a lightsheet comprising;

a substrate;

disposed on the substrate, (i) first and second spaced-apart power conductors and

(ii) a plurality of conductive traces; and

a plurality of light-emitting strings, each light-emitting string (i) comprising a plurality of interconnected light-emitting elements spaced along the light-emitting string, (ii) having a first end electrically coupled to the first power conductor, and (iii) having a second end electrically coupled to the second power conductor, wherein the power conductors supply power to the light-emitting strings,

wherein the lightsheet is separable, via a cut spanning the first and second power conductors and not crossing a light-emitting string, into two partial lightsheets each comprising (i) one or more light-emitting strings, and (ii) portions of the first and second power conductors configured to supply power to and thereby illuminate the one or more light-emitting strings of the partial lightsheet.

2. The lighting system of claim 1, wherein the lightsheet comprises one or more control elements each configured to utilize power supplied from the power conductors to control the current one or more of the light-emitting strings.

3. The lighting system of claim 2, wherein each of the two partial lightsheets comprises at least one control element.

4. The lighting system of claim 2, wherein the one or more control elements comprises a plurality of control elements each electrically connected to a different light-emitting string.

5. The lighting system of claim 4, wherein, for each light-emitting string, light-emitting elements thereof are spaced apart at a substantially constant light-emitting-element pitch independent of a position of the control element electrically connected to the light-emitting string.

6. The lighting system of claim 2, wherein at least one control element is configured to provide a substantially constant current to at least one light-emitting string.

7. The lighting system of claim 2, wherein at least one control element is (i) electrically connected to at least one light-emitting string, and (ii) configured to control an optical characteristic of the light-emitting elements of the at least one light-emitting string to which it is electrically connected.

8. The lighting system of claim 7, wherein the optical characteristic comprises at least one of light intensity, output power, color temperature, color rendering index, or light distribution pattern.

9. The lighting system of claim 2, further comprising a second control element (i) electrically connected to at least one light-emitting string, and (ii) configured to control the at least one light-emitting string to produce an optical characteristic of light emitted thereby.

10. The lighting system of claim 8, wherein the optical characteristic comprises at least one of light intensity, output power, color temperature, color rendering index, or light distribution pattern.

11. The lighting system of claim 2, further comprising a second control element configured to supply power to the power conductors.

12. The lighting system of claim 2, wherein at least one power conductor is configured to provide a control signal to at least one control element.

13. The lighting system of claim 2, wherein the plurality of light-emitting strings comprises at least two groups of light-emitting strings, each group of light emitting-strings having a different optical characteristic controlled by at least one of the one or more control elements.

14. The lighting system of claim 2, wherein at least one of the one or more control elements is configured to communicate, to a control system, at least one of lighting system temperature, light output value, lighting system operation time, lighting system lumen degradation, or lighting system color temperature.

15. The lighting system of claim 1, wherein the weight per area of the lightsheet is less than 1000 gm/m².

16. The lighting system of claim 1, wherein the lightsheet is flexible.

17. The lighting system of claim 1, wherein a thickness of the lightsheet is less than 2 mm.

18. The lighting system of claim 1, further comprising an optical element disposed above and spaced apart from the lightsheet, wherein a collective thickness of the optical element and the lightsheet is less than 40 mm.

19. The lighting system of claim 1, further comprising, electrically connected to the power conductors, a power supply configured to provide a substantially constant voltage to the power conductors.

20. The lighting system of claim 19, further comprising a second lightsheet (i) coupled to the lightsheet and (ii) comprising third and fourth spaced-apart power conductors disposed thereon, wherein the power supply is configured to supply the substantially constant voltage to the third and fourth power conductors.

21. The lighting system of claim 19, wherein the power supply is configured to adjust a light output of the lightsheet by pulse-width-modulating the substantially constant voltage.

22. The lighting system of claim 1, wherein the conductive traces comprise at least one of copper, brass, aluminum, silver, or gold.

23. The lighting system of claim 1, wherein (i) a thickness of the conductive traces is less than 50 μ

m, and (ii) the lightsheet comprises polyethylene terephthalate.

24. The lighting system of claim 1, wherein each light-emitting string comprises only 12, 16, 18, or 20, 60, 72, 84, 90, 96, 108, 120, 126, 140, 150, 156, 160, 168, 180, 198, 200, 204, 210, or 216 light-emitting elements.

25. The lighting system of claim 1, wherein light-emitting elements of each light-emitting string are connected in series.

26. The lighting system of claim 1, wherein at least one light-emitting element emits substantially white light.

27. The lighting system of claim 1, wherein at least one light-emitting element comprises a bare-die light-emitting diode.

28. The lighting system of claim 1, wherein at least one light-emitting element comprises a packaged light-emitting diode.

29. The lighting system of claim 1, wherein at least one light-emitting string is a folded string having a straight-line length longer than a dimension of the lightsheet spanned by the power conductors.

30. The lighting system of claim 29, wherein (i) the light-emitting elements of the folded string have a positive terminal and a negative terminal, and (ii) all of the positive terminals are oriented toward a single edge of the substrate notwithstanding folds in the folded string.

31. The lighting system of claim 1, wherein, in at least one light-emitting string, each light-emitting element is coupled to conductive traces on the substrate via at least one of (i) a conductive adhesive, (ii) an anisotropic conductive adhesive, (iii) a wire bond, or (iv) solder.

32. The lighting system of claim 31, wherein, in at least one light-emitting string, each light-emitting element is coupled to conductive traces on the substrate via an anisotropic conductive adhesive activatable via application of at least one of pressure, heat, or a magnetic field.

33. The lighting system of claim 1, further comprising an insulating layer disposed over (i) at least portions of some of the conductive traces, (ii) at least a portion of at least one of the first or second power conductors, (iii) at least a portion of the substrate, and/or (iv) at least portions of some of the light-emitting elements.

34. The lighting system of claim 1, further comprising an array of optical elements each associated with at least one light-emitting element, the array of optical elements at least one of focusing or shaping light from the light-emitting elements to a desired illumination pattern.

35. The lighting system of claim 1, further comprising a control element configured to supply power to the first and second power conductors.

36. The lighting system of claim 35, wherein the control element is configured to adjust a light output of the lighting system.

37. The lighting system of claim 35, wherein at least a portion of the control element is not disposed on the substrate.

38. The lighting system of claim 35, wherein the control element is configured to communicate, to a control system, at least one of lighting system temperature, light output value, lighting system operation time, lighting system lumen degradation, or lighting system color temperature.

39. The lighting system of claim 35, wherein the plurality of light-emitting strings comprises at least two groups of light-emitting strings, each group of light emitting-strings having a different optical characteristic controlled by the control element.

40. The lighting system of claim 39, wherein at least one said optical characteristic comprises at least one of light intensity, output power, color temperature, color rendering index, or light distribution pattern.