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US 2012/0238045 A1Published application
Three dimensional light emitting diode systems, and compositions and methods relating thereto
AssigneeE. I. Du Pont de Nemours and Company
InventorKURT DOUGLAS ROBERTS
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Abstract
A flexible layered structure is disclosed having a flexible top conductive layer, a flexible bottom heat sink layer and a flexible dielectric middle layer. The combination has a longitudinal axis and a plurality of defined positions spaced along the longitudinal axis. The defined positions can be used for aligning a circuit and/or for the placement of LED lights. The flexible layered structure can be easily bent to form a LED substrate for shining light in more than one direction while efficiently removing heat arising from the LEDs.
Claims5
A method of making an LED lighting assembly comprising:
- a) pulling a flexible layered structure from a reel or from a stack of panels or sheets, the flexible layered structure comprising:
- i. a flexible top conductive layer comprising a first conductive metal, the flexible top conductive layer having a thickness from 4 to 200 microns;
- ii. a flexible bottom heat sink layer comprising a second conductive metal and the flexible bottom heat sink layer having a thickness of at least 50 microns;
- iii. a flexible dielectric middle layer comprising a polymer, the flexible dielectric middle layer having a thickness from 4 to 100 microns and providing electrical insulation between the flexible top conductive layer and the flexible bottom heat sink layer;
- iv. a heat sink adhesive layer;
- and
- v. a release liner
- wherein the first conductive metal of the flexible top conductive layer being the same or different from the second conductive metal of the flexible bottom heat sink layer, and
- the flexible layered structure has a longitudinal axis and a plurality of defined positions spaced along the longitudinal axis, the flexible layered structure being bendable at least 10 degrees proximate at least one of the plurality of defined positions spaced along the longitudinal axis and the flexible layered structure also being twistable relative to the longitudinal axis,
- b) removing the release liner thereby exposing a the heat sink adhesive layer,
- c) applying the heat sink adhesive layer to a secondary heat sink, thereby adhering at least a portion of the flexible layered structure to the secondary heat sink;
- d) configuring the flexible layered structure with the release liner removed into a three dimensional configuration;
- wherein at any time before, during or after during the above method steps, the flexible top conductive layer is circuitized and thereafter at least two LEDs are applied to the flexible top conductive layer of the flexible layered structure.
10 more elements
Dependencies are inferred from the claim text.