Flexible lighting device having unobtrusive conductive layers

• US 9,917,237 B2
• Filed: 11/30/2016
• Issued: 03/13/2018
• 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: Corwin, William L., Gramlich, Jr., Donald Lee, Jones, Scott J., Marx, Martin J., Perez-Bolivar, Cesar, Richardson, II, George M., Roberts, James E.
• Primary Examiner(s): WILCZEWSKI, MARY A
• Application Number:
  US15/364,810
• Publication Number:
  US 20170084807A1
• Time in Patent Office: 468 Days
• CPC Class Codes: H01L 2224/16 of an individual bump connector
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 2933/0066 relating to arrangements for conducting electric current to or from the semiconductor body
• 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
• CPC Class Codes: H05K 1/028 Bending or folding regions of flexible printed circuits H05K1/0283 takes precedence

Abstract

A flexible lighting element is provided, comprising: a first substrate; first and second conductive elements over the first substrate; a light-emitting element having first and second contacts that are both on a first surface of the light-emitting element, the first and second contacts being electrically connected to the first and second conductive elements, respectively, and the light-emitting element emitting light from a second surface opposite the first surface; a transparent layer located adjacent to the second surface; and a transparent affixing layer located between the first substrate and the transparent layer, wherein the transparent layer and the transparent affixing layer are both sufficiently transparent to visible light that they will not decrease light transmittance below 70%, and the first and second conductive layers 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 method of forming a lighting element, comprising:

forming a first substrate;

applying a first conductive element over the first substrate;

applying a second conductive element over the first substrate;

installing a light-emitting element over the first substrate such that a first contact of the light-emitting element is electrically connected to the first conductive element and such that a second contact of the light-emitting element is electrically connected to the second conductive element, the first and second contacts both being on a first surface of the light-emitting element;

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

forming an affixing layer over the first substrate; and

forming a transparent layer over the light-emitting element and the affixing layer such that the affixing layer affixes the transparent layer to the first substrate,

wherein

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

the light-emitting element is configured to emit light having a first narrow range of wavelengths between 10 nm and 100,000 nm from the second surface; and

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

2. The method of claim 1, wherein

the light-emitting element is an ultrathin light-emitting element, having a thickness of between 3 mil and 20 mil.

3. The method of claim 1, wherein

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

4. The method of claim 1, wherein

the first and second conductive elements each comprise at least one of a conductive polymer strip, a nano-composite strip, a metal nanowire, a copper strip, an aluminum strip, a silver strip, and a strip containing an alloy of copper, aluminum, or silver.

5. The method of claim 1, wherein

the first substrate is sufficiently transparent to visible light such that it will not decrease light transmittance below 70%.

6. The method of claim 1, wherein

the first and second conductive elements are both buss bars.

7. The method of claim 1, further comprising:

forming a second transparent conductive layer at least partially adjacent to the second contact and at least partially adjacent to the second conductive element, the second transparent conductive layer being 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 it will not decrease light transmittance below 70%.