Flexible lighting device having both visible and infrared light-emitting diodes

• US 10,032,753 B2
• Filed: 06/20/2014
• Issued: 07/24/2018
• Est. Priority Date: 06/20/2014
• 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., Brooks, Timothy W., Gramlich, Jr., Donald L., Corwin, William L., Robbins, Stanley D.
• Primary Examiner(s): Kryukova, Erin
• Application Number:
  US14/310,538
• Publication Number:
  US 20150371972A1
• Time in Patent Office: 1,495 Days
• Field of Search: 257 88, 257 89, 257 99, 257724, 257725, 438 28
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• 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: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01L 2933/005 relating to encapsulations
• CPC Class Codes: H01L 2933/0066 relating to arrangements for conducting electric current to or from the semiconductor body
• CPC Class Codes: H01L 33/52 Encapsulations
• 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 flexible lighting array, comprising: a flexible substrate; a pair of first electrical connectors formed on the flexible substrate; a pair of second electrical connectors formed on the flexible substrate; an isolation element formed on the flexible substrate between the pair of first electrical connectors and the pair of second electrical connectors; a plurality of first light-emitting elements formed over the pair of first electrical connectors; one or more second light-emitting elements formed over the pair of second electrical connectors; and a transparent covering layer formed over the plurality of first light-emitting elements and the one or more second light-emitting elements, wherein, the plurality of first light-emitting elements are configured to emit visible light in a wavelength range of 200 nm to 800 nm, and the one or more second light-emitting elements are configured to emit infrared light in a wavelength range of 800 nm to 1200 nm.

Claims

1. A flexible lighting array, comprising:

a flexible substrate capable of freely bending and returning to its original shape;

a pair of first electrical connectors formed on the flexible substrate;

a pair of second electrical connectors formed on the flexible substrate;

an electrical isolator formed on the flexible substrate and surrounded by at least one material layer on the flexible substrate between the pair of first electrical connectors and the pair of second electrical connectors;

a plurality of first light-emitting elements formed over the pair of first electrical connectors, the first light emitting elements being light-emitting diodes each having a first anode and a first cathode;

one or more second light-emitting elements formed over the pair of second electrical connectors, the second light emitting elements being light-emitting diodes each having a second anode and a second cathode; and

a transparent covering layer formed over the plurality of first light-emitting elements and the one or more second light-emitting elements,

wherein,

the plurality of first light-emitting elements are configured to emit visible light in a wavelength range of 200 nm to 800 nm, and

the one or more second light-emitting elements are configured to emit infrared light in a wavelength range of 800 nm to 1200 nm.

2. The flexible lighting array of claim 1, wherein the first and second light-emitting elements are light-emitting diodes.

3. The flexible lighting array of claim 1, wherein the plurality of first light-emitting elements are configured to emit light in a wavelength range of 620 nm to 650 nm.

4. The flexible lighting array of claim 1, wherein the plurality of first elements are formed into a first pattern.

5. The flexible lighting array of claim 4, wherein

the one or more second light-emitting elements formed over the pair of second electrical connectors are two or more second light-emitting elements formed over the pair of second electrical connectors, and

the two or more second light-emitting elements are formed into a second pattern different from the first pattern.

6. The flexible lighting array of claim 1, wherein the flexible substrate is attached to one of clothing or a vehicle.

7. The flexible lighting array of claim 1, wherein the plurality of first light-emitting elements and the one or more second light-emitting elements are within 12.5 micrometers of being the same height.

8. The flexible lighting array of claim 1, wherein the transparent covering layer is one of a transparent upper substrate or a transparent conformal coat.

9. The flexible lighting array of claim 1, wherein the flexible substrate comprises one of polyethylene terephthalate (PET), polyethylene napthalate (PEN), polyester, an oxide-coated polymer, or a metal-coated flexible plastic.

10. The flexible lighting array of claim 1, further comprising:

an affixing layer formed over the flexible substrate and around the first light-emitting elements, the affixing layer fixing the visible light-emitting elements and the transparent covering layer in place.

11. The flexible lighting array of claim 1, wherein

the transparent covering layer is a conformal coating, and

the conformal coating is formed on top of and around the first light-emitting elements, and serves to fix the first light-emitting elements in place.

12. The flexible lighting array of claim 10, wherein

the affixing layer contacts the first light-emitting element along an entire height of the first light-emitting element, and

the isolator is formed into the affixing layer and the affixing layer is the at least one material layer.

13. A method of manufacturing a flexible lighting array, comprising:

forming a flexible substrate capable of freely bending and returning to its original shape;

forming a pair of first electrical connectors on the flexible substrate;

forming a pair of second electrical connectors on the flexible substrate;

forming an electrical isolator on the flexible substrate such that the electrical isolator is surrounded by at least one material layer between the pair of first electrical connectors and the pair of second electrical connectors;

depositing a plurality of first light-emitting elements over the pair of first electrical connectors, the first light emitting elements being light-emitting diodes each having a first anode and a first cathode;

depositing one or more second light-emitting elements over the pair of second electrical connectors, the second light emitting elements being light-emitting diodes each having a second anode and a second cathode; and

forming a transparent covering layer over the plurality of first light-emitting elements and the one or more second light-emitting elements,

wherein,

the plurality of first light-emitting elements are configured to emit visible light in a wavelength range of 200 nm to 800 nm, and

the one or more second light-emitting elements are configured to emit infrared light in a wavelength range of 800 nm to 1200 nm.

14. The method of claim 13, wherein the first and second light-emitting elements are light-emitting diodes.

15. The method of claim 13, wherein the plurality of first light-emitting elements are configured to emit light in a wavelength range of 620 nm to 650 nm.

16. The method of claim 13, wherein in the depositing of the plurality of first light-emitting elements, the plurality of first light-emitting elements are formed into a first pattern.

17. The method of claim 16, wherein in the depositing of the one or more second light-emitting elements, the one or more second light-emitting elements are formed into a second pattern different from the first pattern.

18. The method of claim 13, further comprising

attaching the flexible substrate to an article of clothing.

19. The method of claim 13, further comprising

attaching the flexible substrate to a vehicle.

20. The method of claim 13, wherein the plurality of first light-emitting elements and the one or more second light-emitting elements are within 12.5 micrometers of the same height.

21. The method of claim 13, wherein the transparent covering layer is one of a transparent upper substrate or a transparent conformal coat.

22. The method of claim 13, wherein the flexible substrate comprises one of polyethylene terephthalate (PET), polyethylene napthalate (PEN), polyester, an oxide-coated polymer, or a metal-coated flexible plastic.

23. The method of claim 13, further comprising:

forming an affixing layer over the flexible substrate and around the two or more first light-emitting elements,

wherein

the transparent covering layer is formed over the affixing layer, and

the affixing layer fixes the visible light-emitting elements and the transparent covering layer in place.

24. The method of claim 13, wherein

the transparent covering layer is a conformal coating, and

the conformal coating is formed on top of and around the first light-emitting elements, and serves to fix the first light-emitting elements in place.

25. The method of claim 24,

wherein the transparent covering layer is in a viscous form during the operation of forming a transparent covering layer over the plurality of first light-emitting elements and the one or more second light-emitting elements,

the method further comprising hardening the transparent covering layer using heat or ultraviolet radiation after the operation of forming the transparent covering layer.

26. The method of claim 23, wherein

the affixing layer contacts the first light-emitting element along an entire height of the first light-emitting element, and

the isolator is formed into the affixing layer and the affixing layer is the at least one material layer.