WO2009098636A1 - Light emitting sheet - Google Patents

Light emitting sheet Download PDF

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Publication number
WO2009098636A1
WO2009098636A1 PCT/IB2009/050431 IB2009050431W WO2009098636A1 WO 2009098636 A1 WO2009098636 A1 WO 2009098636A1 IB 2009050431 W IB2009050431 W IB 2009050431W WO 2009098636 A1 WO2009098636 A1 WO 2009098636A1
Authority
WO
WIPO (PCT)
Prior art keywords
electrically conductive
light emitting
layer
conductive layer
led
Prior art date
Application number
PCT/IB2009/050431
Other languages
French (fr)
Inventor
Maarten M. J. W. Van Herpen
Original Assignee
Koninklijke Philips Electronics N.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Koninklijke Philips Electronics N.V. filed Critical Koninklijke Philips Electronics N.V.
Publication of WO2009098636A1 publication Critical patent/WO2009098636A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/62—Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/52—Encapsulations
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/52—Encapsulations
    • H01L33/54—Encapsulations having a particular shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
    • H01L24/80—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected
    • H01L24/82—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected by forming build-up interconnects at chip-level, e.g. for high density interconnects [HDI]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/10—Details of semiconductor or other solid state devices to be connected
    • H01L2924/11—Device type
    • H01L2924/12—Passive devices, e.g. 2 terminal devices
    • H01L2924/1204—Optical Diode
    • H01L2924/12041—LED

Definitions

  • the present invention relates to a light emitting sheet provided with an embedded LED, the sheet having a multi-layer structure.
  • Light output devices utilizing light emitting diodes (LEDs) as their light sources have become increasingly popular. Such light output devices can be used for illumination of objects, for display of an image, or simply for decorative purposes.
  • a light output device is a light emitting sheet provided with an embedded LED.
  • embedded means that an element is fully or partly surrounded by another material in such a way that the element does not protrude from the material.
  • LEDs are made by connecting the n-type semiconductor region and the p-type semiconductor region of an LED chip to respective terminal pins for drawing electric current.
  • the LED chip is embedded in a package, for example of a resin.
  • the package may be arranged so that light from the LED chip is emitted in one or more designated directions.
  • the part of the LED containing the LED chip is referred as a light emitting body.
  • US-A 7221007 discloses a sheet for optical-element encapsulation, which has a multilayer structure including at least two resin layers.
  • the at least two resin layers include: an outermost resin layer that is to be brought into contact with one or more optical semiconductor elements; and a resin layer disposed on the first-mentioned layer. This sheet is superposed on an optical semiconductor element(s)-mounted side of a wiring circuit board so that the outermost resin layer is brought into contact with the optical semiconductor element(s).
  • This object is achieved by the present invention which provides a light emitting sheet provided with an embedded LED, the sheet having a multilayer structure comprising: a first electrically conductive layer and a second electrically conductive layer and - an electrically insulating layer provided between the first electrically conductive layer and the second electrically conductive layer, wherein the LED has a light emitting body, a first terminal pin and a second terminal pin, the first terminal pin and the second terminal pin being mechanically and electrically connected to the first and the second electrically conductive layer, respectively.
  • the terminal pins are in direct contact with the respective electrically conductive layers.
  • the terminal pins may be embedded in or partly encapsulated in the layers.
  • the electrically conductive layers sandwiching an electrically insulating layer is used for the electrical connection of the LED or LEDs. This makes the wire-bonding process of the terminal pins unnecessary, which is required in the manufacturing processes of conventional light emitting sheets. This leads to an easier manufacturing process.
  • the pins may be conventional LED pins, made of an electrically conductive material, such as a metal. They can have a rod-like, round, plate-like or any other suitable shape. Furthermore, there is a great degree of freedom in cutting the light emitting sheet to a desired shape or length.
  • an LED itself should not be cut. It is even possible to cut off a part of the light emitting sheet while the light emitting sheet is operating and let the remaining part of the sheet keep operating.
  • an embodiment where the electrically conductive layers have uncovered, connectable rims provides a possibility of increasing or decreasing the area of light emission during operation by connecting or disconnecting a further sheet sidewise to the light emitting sheet in operation.
  • a further advantage is that the structure may be flexible.
  • the light emitting body of the LED is embedded in the multilayer structure, the first electrically conductive layer having an outer surface and an inner surface, the second electrically conductive layer having an outer surface and an inner surface and the electrically insulating layer provided between the inner surface of the first electrically conductive layer and the inner surface of the second electrically conductive layer, the multilayer structure being at least partly permeable to light for allowing transmission of the light from the LED to at least one of the first electrically conductive layer and the second electrically conductive layer.
  • the light emitting body is embedded between the outer surfaces of the first and the second electrically conductive layer, so there is no need for additional layers to ensure that there is no protrusion of the LEDs from the sheet.
  • a surface of the light emitting body may coincide with the outer surface of the first or the second electrically conductive layer. In this case, light is emitted from the light emitting sheet even when the multilayer structure is made of a non-translucent material.
  • the LED is arranged to emit light from a first surface of the light emitting body, which first surface faces the outer surface of the first electrically conductive layer, and the multilayer structure has a substantially translucent portion between the first surface of the light emitting body and the outer surface of the first electrically conductive layer.
  • the light is emitted, during use, perpendicular to the multilayer structure, through a light emitting surface parallel to the multilayer structure.
  • the light emitting body is fully encapsulated in the multilayer structure, without any part of the light emitting body being exposed to the outside.
  • the multilayer structure protects the LED from damage. Light is emitted out of the light emitting sheet from the first electrically conductive layer.
  • the first surface of the light emitting body is in the first electrically conductive layer, only the first electrically conductive layer needs to have a translucent portion.
  • the first surface is in the second electrically conductive layer, all of the first electrically conductive layer, the electrically insulating layer and the second electrically conductive layer must have a translucent portion.
  • the LED is arranged to emit light from a second surface of the light emitting body, which second surface faces the outer surface of the second electrically conductive layer, and the multilayer structure has a substantially translucent portion between the second surface of the light emitting body and the outer surface of the second electrically conductive layer.
  • the electrically insulating layer is substantially translucent and the light emitting body of the LED is embedded in the electrically insulating layer.
  • the LED is arranged to emit light in a direction substantially parallel to the multilayer structure.
  • light scattering particles are embedded in the multilayer structure.
  • the light scattering particles may be e.g. TiO 2 , ZrO 2 or MgO.
  • the light is scattered by the light scattering particles, and eventually it is emitted from one or both outer sides of the electrically conductive layers. This allows a more uniform light output from the light emitting sheet instead of the sheet having point light sources.
  • the diameters of the light scattering particles may be e.g. 100 nm to 2 ⁇ m.
  • the amount of the light scattering particles may be in a range of 0.01-2 %, preferably 0.01-0.5% by weight.
  • the degree of scattering may be controlled by the amount of the scattering particles as well as the sizes of the scattering particles.
  • the light scattering particles may be embedded in the multilayer structure in embodiments where the LED emits light from the above-mentioned first or second surfaces of the light emitting body, preferably in a substantially perpendicular direction to the multilayer structure. Also in such embodiments, the light scattering particles give a more uniform light output from the light emitting sheet.
  • the multilayer structure further comprises: a bottom electrically insulating layer provided on the outer surface of the first electrically conductive layer and a top electrically insulating layer provided on the outer surface of the second electrically conductive layer, wherein the light emitting body of the LED is embedded in the multilayer structure, the multilayer structure being at least partly permeable to light for allowing transmission of the light from the LED to at least one of a surface of the bottom electrically insulating layer remote from the outer surface of the first electrically conductive layer and a surface of the top electrically insulating layer remote from the outer surface of the second electrically conductive layer.
  • the additional electrically insulating layers of the multilayer structure provide electrical safety and an improved protection against mechanical stress.
  • the LED or LEDs may be fully encapsulated in one of these additional electrically insulating layers. A great freedom is obtained in the positioning and construction of each LED.
  • At least one of the bottom electrically insulating layer and the bottom electrically insulating layer mainly comprises a translucent rubber.
  • the rubber may be a natural rubber or a synthetic rubber.
  • one of the top electrically insulating layer and the bottom electrically insulating layer is reflective.
  • the reflectivity may be given by coating a reflective material or the insulating layers may be made of a reflective material.
  • the reflective layer on one side of the multilayer structure allows an intensified light emission from the other side of the multilayer structure.
  • the first terminal pin has a first part which penetrates through the second electrically conductive layer and a second part which penetrates through the electrically insulating layer, the first part being covered with an insulation cover. This allows a greater freedom in the positioning of the LEDs by allowing e.g. the light emitting body to be fully encapsulated in the second electrically conductive layer. It is ensured that the first terminal pin is electrically isolated from the second electrically conductive layer.
  • the electrically insulating layer between the first and the second electrically conductive layers mainly comprises a translucent rubber.
  • the layers are plastic materials.
  • the conductive layers are translucent electrically conductive plastics, such as for example electrically conductive PVB (Poly- vinyl butyral with embedded silver particles), optionally with embedded light scattering particles (for example TiO 2 particles).
  • the electrically isolating layers translucent electrically isolating plastics.
  • PVB or PMMA may be used for this layer.
  • the first and the second electrically conductive layers mainly comprise a translucent rubber embedded with electrically conductive particles.
  • the manufacturing process is simpler when the conductive layers and the insulating layers have the same base material.
  • the light emitting sheet further comprises embedded electronics for controlling the light output from each of the LEDs. These electronics may be, for example, microcontrollers and resistors or capacitors. Current control may be needed when the LEDs used have different driving characteristics and thus cannot all be connected to the same voltage.
  • an illumination system comprising a light emitting sheet according to the present invention and a power source connected or connectable to the first electrically conductive layer and the second electrically conductive layer.
  • An illumination system is obtained just by connecting the first electrically conductive layer and the second electrically conductive layer to a power source. It will be appreciated that a further controller of the current provided to the LED or LEDs may be used for controlling the illumination from each LED of the light emitting sheet.
  • the sheet may be formed into a tire shape or a form which can be incorporated into a tire. Also the light emitting sheet may be used for a fabric, and a piece of clothing which emits light may be made with such a fabric. Furthermore, a light emitting doormat may be made.
  • a light emitting sheet device comprising a plurality of light emitting sheets according to the present invention by providing an electrically insulating separation layer between neighboring light emitting sheets. This may form an illumination system,
  • a method of manufacturing a light emitting sheet provided with an embedded LED comprising the steps of: providing a first layer mainly comprising an uncured translucent rubber containing electrically conductive particles; immersing the LED into the first layer such that the first terminal pin is at least partly immersed in and in electrical contact with the first layer; curing the first layer to form a first electrically conductive layer; providing a layer mainly comprising the uncured translucent rubber on top of the first electrically conductive layer; curing the layer mainly comprising an uncured translucent rubber to form a electrically insulating layer; providing a second layer mainly comprising the uncured translucent rubber containing the electrically conductive particles on top of the electrically insulating layer, such that the second terminal pin is at least partly immersed in and in electrical contact with the second layer; and curing the second layer to form a second electrically conductive layer.
  • the method further comprises the steps of: prior to the step of providing the first layer, providing a bottom layer mainly comprising an uncured translucent rubber, and curing the bottom layer to form a bottom electrically insulating layer onto which the first layer is to be provided; and providing a top layer mainly comprising an uncured translucent rubber on top of the second electrically conductive layer, and curing the top layer to form the top electrically insulating layer.
  • the invention further relates to a light emitting sheet mentioned above comprising further correspondingly embedded LEDs or a light emitting sheet manufactured by a method mentioned above comprising further correspondingly embedded LEDs.
  • Figure 1 schematically illustrates a cross sectional view of an embodiment of the light emitting sheet according to the invention
  • Figure 2a-c schematically illustrate a cross sectional view of various embodiment of the light emitting sheet according to the invention
  • Figure 3 schematically illustrates a cross sectional view of a further embodiment of the light emitting sheet according to the invention
  • Figure 4 schematically illustrates a cross sectional view of a further embodiment of the light emitting sheet according to the invention
  • Figure 5 schematically illustrates in a perspective view an embodiment of the light emitting sheet according to the invention during operation
  • Figure 6 schematically illustrates a cross sectional view of an embodiment of a tire comprising the light emitting sheet according to the invention during operation
  • Figure 7a-e schematically illustrate an exemplary method of manufacturing the light emitting sheet according to the invention using translucent rubber.
  • FIG. 1 a schematic cross section of an embodiment of a light emitting sheet 100 according to the present invention is shown.
  • a plurality of LEDs of which an LED 10 is depicted, is embedded in the light emitting sheet 100.
  • the light emitting sheet 100 comprises a first electrically conductive layer 20 having an outer surface 21 and an inner surface 22, a second electrically conductive layer 30 having an outer surface 31 and an inner surface 32 and an electrically insulating layer 40 provided between the inner surface 22 of the first electrically conductive layer 20 and the inner surface 32 of the second electrically conductive layer 31.
  • the first terminal pin 12 and the second terminal pin 13 are embedded in the first and the second electrically conductive layer 20, 30, respectively.
  • the light emitting body 11 of the LED 10 is embedded in the multilayer structure of the first electrically conductive layer 20, the electrically insulating layer 40 and the second electrically conductive layer 30.
  • the light emitting body 11 of the LED 10 has a first surface 11a having a portion closest to the outer surface 21 of the first electrically conductive layer 20 and a second surface 1 Ib having a portion closest to the outer surface 31 of the second electrically conductive layer 30.
  • the LED 10 may be arranged to emit light from both the first and the second surface 1 Ia, 1 Ib, or also from other surfaces.
  • the multilayer structure constituted by the first electrically conductive layer 20, the electrically insulating layer 40 and the second electrically conductive layer 30 may be substantially translucent.
  • the first and the second electrically conductive layer 20, 30 may mainly comprise a translucent rubber embedded with electrically conductive particles.
  • the electrically insulating layer 40 may mainly comprise a translucent rubber.
  • the rubber may be a natural rubber or a synthetic rubber.
  • the translucent property of the multilayer structure allows the light from the first and the second surface 11a, 1 Ib to be emitted from both sides of the light emitting sheet 100.
  • only one of the two electrically conductive layers 20, 30 may be substantially translucent. In this case, light will be emitted from only one side of the light emitting sheet 100.
  • the portions of the multilayer structure between the first and/or the second surface 11a, 1 Ib and the outer surface 21, 31 of the first or the second electrically conductive layer 20, 30, respectively, may be substantially translucent.
  • the electrically conductive layers 20 and 30 are patterned in order to make them partially translucent.
  • the conductive layer may have holes which are filled with a non-conductive, but translucent rubber.
  • the first surface 11a of the light emitting body 11 coincides with the outer surface 21 of the first electrically conductive layer 20.
  • the multilayer structure does not have to have a translucent portion for the light to be emitted from the outer surface 21 of the first electrically conductive layer.
  • the light emitting body 11 is embedded in the electrically insulating layer 40.
  • the terminal pins 12, 13 are also embedded in the electrically insulating layer 40, but are physically and electrically connected to the first and the second electrically conductive layer 20,30, respectively.
  • the light emitting body is fully encapsulated in the first electrically insulating layer 20 without contacting the electrically insulating layer 40.
  • a second terminal pin 13 reaches the second electrically insulating layer 30 by penetrating through the first electrically conductive layer 20 with a first part and through the electrically insulating layer 40 with a second part.
  • the first part is covered by an insulating cover 80 in order to ensure that the second terminal pin 13 does not make an electrical contact with the first electrically conductive layer 20.
  • the insulating cover 80 may be made of the same material as the electrically insulating layers 20, 30.
  • embedded light scattering particles 70 scatter the light, and light will be emitted out of the light emitting sheet.
  • the light scattering particles may be e.g. TiO 2 , ZrO 2 or MgO.
  • the diameters of the light scattering particles may be e.g. 100 nm to 2 ⁇ m.
  • the amount of the light-scattering particles may be in a range of 0.01-2 %, preferably 0.01-0.5% by weight.
  • the degree of scattering may be controlled by the amount of the scattering particles as well as the sizes of the scattering particles.
  • the light emitting sheet 100 further comprises a bottom electrically insulating layer 50 provided on the outer surface 21 of the electrically conductive layer 20 and a top electrically insulating layer 60 provided on the outer surface 31 of the electrically conductive layer 30.
  • the light emitting body 10 is embedded in the bottom layer 50.
  • the LED may be arranged to emit light in a direction perpendicular to the multilayer structure.
  • the bottom insulating layer 50 may be substantially translucent for the light to be emitted from the light emitting sheet 100.
  • the top insulating layer 60 may be reflective. In this case, light transmitted through the multilayer to the top insulating layer 60 will be reflected and be emitted from the bottom electrically insulating layer 50.
  • Figure 5 schematically shows an embodiment of the light emitting sheet 100 according to the present invention, provided with a plurality of LEDs, during operation.
  • the LEDs 10 emit light when the electrically conductive layers 20, 30 are connected to the power source.
  • the part of the light emitting sheet 100 no longer connected to the power source shown in the left of the drawing, will stop emitting light. If this left part is contacted again to the part still connected to the power source, it will start to emit light again.
  • Figure 6 schematically shows a cross sectional view of an embodiment of a tire comprising a light emitting sheet 100 according to the present invention.
  • the light emitting sheet 100 can be formed into a round shape of a tire.
  • the light can be emitted from the surface of the tire which contacts the ground. It will be appreciated that the light can be emitted in any direction by suitably arranging the structure of the tire. For example, light can be emitted from the side of the tire in a direction perpendicular to the surface of the tire which contacts the ground.
  • Figures 7a-e schematically illustrate an exemplary method of manufacturing the light emitting sheet according to the invention using a translucent rubber.
  • a first layer 20a of an uncured translucent rubber embedded with electrically conductive particles is applied on top of a bottom electrically insulating layer 50. While the first layer 20a is in a liquid form, an LED 10 is immersed into the first layer, as illustrated in figure 7b. The immersion is done in such a way that the first terminal pin 12 of the LED 50 is at least partly immersed in the first layer 20a. Subsequently the first layer 20a is cured to form a first electrically conductive layer 20, for example with vulcanization, or any other suitable means for curing the rubber.
  • a layer 40a of an uncured translucent rubber is applied on top of the first electrically conductive layer 22, as illustrated in figure 7c. Subsequently the layer 40a is cured to form an electrically insulating layer 40.
  • a layer 30a of an uncured translucent rubber embedded with electrically conductive particles is applied on top of the electrically insulating layer 40, as illustrated in figure 7d. The amount of the material of the layer 30a is selected so that the second terminal pin 13 is at least partly immersed in the second layer 30a. Subsequently the second layer 30a is cured to form a first electrically conductive layer 30.
  • another layer 60a of an uncured translucent rubber is applied on top of the second electrically conductive layer 30. Subsequently the layer 60a is cured to form a top electrically insulating layer 60. It is noted that the curing process of each of the layers may be performed in two or more steps. The layer may be partially cured before the subsequent layer is applied. In this case, the adhesion between the layers may be promoted. In such a case, full curing is carried out afterwards.
  • the multilayer structure of the first and the second electrically conductive layers 20, 30 and the electrically insulating layer 40 may be made by the successive curing processes as described above, and electrically insulating layers 50, 60 may then be provided to sandwich the electrically conductive layers 20, 30.
  • the electrically insulating layers 50, 60 may be adhered to the electrically conductive layers 20, 30.
  • any reference signs placed between parentheses shall not be construed as limiting the claim.
  • Use of the verb "comprise” and its conjugations does not exclude the presence of elements or steps other than those stated in a claim.
  • the article “a” or “an” preceding an element does not exclude the presence of a plurality of such elements.
  • the light emitting sheet may comprise more than one LED.
  • the mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
  • the term LED primarily means light emitting diode, but also includes, in this paper, any other optical- semiconductor element, such as laser diode.

Abstract

The present invention relates to a light emitting sheet (100) provided with an embedded LED (10), the sheet having a multilayer structure. This structure comprises a first electrically conductive layer (20) having an outer surface (21) and an inner surface (22), a second electrically conductive layer (30) having an outer surface (31) and an inner surface (32) and an electrically insulating layer (40) provided between the inner surface of the first electrically conductive layer and the inner surface of the second electrically conductive layer. The LED has a light emitting body (11), a first terminal pin (12) and a second terminal pin (13), the first terminal pin and the second terminal pin being mechanically and electrically connected to the first and the second electrically conductive layer, respectively. The light emitting sheet according to the invention can be manufactured in a relatively easy way.

Description

Light emitting sheet
FIELD OF THE INVENTION
The present invention relates to a light emitting sheet provided with an embedded LED, the sheet having a multi-layer structure.
BACKGROUND OF THE INVENTION
Light output devices utilizing light emitting diodes (LEDs) as their light sources have become increasingly popular. Such light output devices can be used for illumination of objects, for display of an image, or simply for decorative purposes. One example of a light output device is a light emitting sheet provided with an embedded LED. As used herein, the term "embedded" means that an element is fully or partly surrounded by another material in such a way that the element does not protrude from the material.
LEDs are made by connecting the n-type semiconductor region and the p-type semiconductor region of an LED chip to respective terminal pins for drawing electric current. The LED chip is embedded in a package, for example of a resin. The package may be arranged so that light from the LED chip is emitted in one or more designated directions. As used herein, the part of the LED containing the LED chip is referred as a light emitting body. US-A 7221007 discloses a sheet for optical-element encapsulation, which has a multilayer structure including at least two resin layers. The at least two resin layers include: an outermost resin layer that is to be brought into contact with one or more optical semiconductor elements; and a resin layer disposed on the first-mentioned layer. This sheet is superposed on an optical semiconductor element(s)-mounted side of a wiring circuit board so that the outermost resin layer is brought into contact with the optical semiconductor element(s).
In this arrangement, electric current is conducted to the optical semiconductor elements by wiring, which is obtained by a wire-bonding process. The arrangement also requires optical semiconductor elements to be mounted in a complex wiring circuit board. This is a rather complex structure, and also the manufacturing process is rather complex. SUMMARY OF THE INVENTION
It is an object of the invention to provide a light emitting sheet provided with one or more LEDs and having such a structure that it can be obtained with a relatively easy manufacturing process. This object is achieved by the present invention which provides a light emitting sheet provided with an embedded LED, the sheet having a multilayer structure comprising: a first electrically conductive layer and a second electrically conductive layer and - an electrically insulating layer provided between the first electrically conductive layer and the second electrically conductive layer, wherein the LED has a light emitting body, a first terminal pin and a second terminal pin, the first terminal pin and the second terminal pin being mechanically and electrically connected to the first and the second electrically conductive layer, respectively. In such a structure, the terminal pins are in direct contact with the respective electrically conductive layers. The terminal pins may be embedded in or partly encapsulated in the layers. The electrically conductive layers sandwiching an electrically insulating layer is used for the electrical connection of the LED or LEDs. This makes the wire-bonding process of the terminal pins unnecessary, which is required in the manufacturing processes of conventional light emitting sheets. This leads to an easier manufacturing process. The pins may be conventional LED pins, made of an electrically conductive material, such as a metal. They can have a rod-like, round, plate-like or any other suitable shape. Furthermore, there is a great degree of freedom in cutting the light emitting sheet to a desired shape or length. The only requirement in cutting the light emitting sheet is that an LED itself should not be cut. It is even possible to cut off a part of the light emitting sheet while the light emitting sheet is operating and let the remaining part of the sheet keep operating. Moreover, an embodiment where the electrically conductive layers have uncovered, connectable rims provides a possibility of increasing or decreasing the area of light emission during operation by connecting or disconnecting a further sheet sidewise to the light emitting sheet in operation. A further advantage is that the structure may be flexible.
According to a preferred embodiment of the invention, the light emitting body of the LED is embedded in the multilayer structure, the first electrically conductive layer having an outer surface and an inner surface, the second electrically conductive layer having an outer surface and an inner surface and the electrically insulating layer provided between the inner surface of the first electrically conductive layer and the inner surface of the second electrically conductive layer, the multilayer structure being at least partly permeable to light for allowing transmission of the light from the LED to at least one of the first electrically conductive layer and the second electrically conductive layer. The light emitting body is embedded between the outer surfaces of the first and the second electrically conductive layer, so there is no need for additional layers to ensure that there is no protrusion of the LEDs from the sheet. A surface of the light emitting body may coincide with the outer surface of the first or the second electrically conductive layer. In this case, light is emitted from the light emitting sheet even when the multilayer structure is made of a non-translucent material.
According to a further embodiment of the invention, the LED is arranged to emit light from a first surface of the light emitting body, which first surface faces the outer surface of the first electrically conductive layer, and the multilayer structure has a substantially translucent portion between the first surface of the light emitting body and the outer surface of the first electrically conductive layer. In this embodiment the light is emitted, during use, perpendicular to the multilayer structure, through a light emitting surface parallel to the multilayer structure. The light emitting body is fully encapsulated in the multilayer structure, without any part of the light emitting body being exposed to the outside. The multilayer structure protects the LED from damage. Light is emitted out of the light emitting sheet from the first electrically conductive layer. The layers in which the light emitting body is embedded, and therefore the position of the first surface within the multilayer structure, determine which layers must have a translucent portion. When the first surface of the light emitting body is in the first electrically conductive layer, only the first electrically conductive layer needs to have a translucent portion. When the first surface is in the second electrically conductive layer, all of the first electrically conductive layer, the electrically insulating layer and the second electrically conductive layer must have a translucent portion.
According to a further embodiment of the invention, the LED is arranged to emit light from a second surface of the light emitting body, which second surface faces the outer surface of the second electrically conductive layer, and the multilayer structure has a substantially translucent portion between the second surface of the light emitting body and the outer surface of the second electrically conductive layer. This arrangement allows light to be emitted from both sides of the light emitting sheet. According to a further embodiment of the invention, the electrically insulating layer is substantially translucent and the light emitting body of the LED is embedded in the electrically insulating layer.
According to a further embodiment of the invention, the LED is arranged to emit light in a direction substantially parallel to the multilayer structure.
According to a further embodiment of the invention, light scattering particles are embedded in the multilayer structure. The light scattering particles may be e.g. TiO2, ZrO2 or MgO. The light is scattered by the light scattering particles, and eventually it is emitted from one or both outer sides of the electrically conductive layers. This allows a more uniform light output from the light emitting sheet instead of the sheet having point light sources. The diameters of the light scattering particles may be e.g. 100 nm to 2μm. The amount of the light scattering particles may be in a range of 0.01-2 %, preferably 0.01-0.5% by weight. The degree of scattering may be controlled by the amount of the scattering particles as well as the sizes of the scattering particles. It will be appreciated that the light scattering particles may be embedded in the multilayer structure in embodiments where the LED emits light from the above-mentioned first or second surfaces of the light emitting body, preferably in a substantially perpendicular direction to the multilayer structure. Also in such embodiments, the light scattering particles give a more uniform light output from the light emitting sheet. According to a further embodiment of the invention, the multilayer structure further comprises: a bottom electrically insulating layer provided on the outer surface of the first electrically conductive layer and a top electrically insulating layer provided on the outer surface of the second electrically conductive layer, wherein the light emitting body of the LED is embedded in the multilayer structure, the multilayer structure being at least partly permeable to light for allowing transmission of the light from the LED to at least one of a surface of the bottom electrically insulating layer remote from the outer surface of the first electrically conductive layer and a surface of the top electrically insulating layer remote from the outer surface of the second electrically conductive layer.
In this arrangement, the additional electrically insulating layers of the multilayer structure provide electrical safety and an improved protection against mechanical stress. The LED or LEDs may be fully encapsulated in one of these additional electrically insulating layers. A great freedom is obtained in the positioning and construction of each LED.
According to a further embodiment of the invention, at least one of the bottom electrically insulating layer and the bottom electrically insulating layer mainly comprises a translucent rubber. The rubber may be a natural rubber or a synthetic rubber.
According to a further embodiment of the invention, one of the top electrically insulating layer and the bottom electrically insulating layer is reflective. The reflectivity may be given by coating a reflective material or the insulating layers may be made of a reflective material. The reflective layer on one side of the multilayer structure allows an intensified light emission from the other side of the multilayer structure.
According to a further embodiment of the invention, the first terminal pin has a first part which penetrates through the second electrically conductive layer and a second part which penetrates through the electrically insulating layer, the first part being covered with an insulation cover. This allows a greater freedom in the positioning of the LEDs by allowing e.g. the light emitting body to be fully encapsulated in the second electrically conductive layer. It is ensured that the first terminal pin is electrically isolated from the second electrically conductive layer.
According to a further embodiment of the invention, the electrically insulating layer between the first and the second electrically conductive layers mainly comprises a translucent rubber.
In another embodiment, the layers are plastic materials. The conductive layers are translucent electrically conductive plastics, such as for example electrically conductive PVB (Poly- vinyl butyral with embedded silver particles), optionally with embedded light scattering particles (for example TiO2 particles). The electrically isolating layers translucent electrically isolating plastics. For example PVB or PMMA may be used for this layer.
According to a further embodiment of the invention, the first and the second electrically conductive layers mainly comprise a translucent rubber embedded with electrically conductive particles. The manufacturing process is simpler when the conductive layers and the insulating layers have the same base material. According to a further embodiment of the invention, the light emitting sheet further comprises embedded electronics for controlling the light output from each of the LEDs. These electronics may be, for example, microcontrollers and resistors or capacitors. Current control may be needed when the LEDs used have different driving characteristics and thus cannot all be connected to the same voltage. According to another aspect of the invention, an illumination system is provided comprising a light emitting sheet according to the present invention and a power source connected or connectable to the first electrically conductive layer and the second electrically conductive layer. An illumination system is obtained just by connecting the first electrically conductive layer and the second electrically conductive layer to a power source. It will be appreciated that a further controller of the current provided to the LED or LEDs may be used for controlling the illumination from each LED of the light emitting sheet.
It is an advantage of the light emitting sheet according to the present invention that various applications are possible. The sheet may be formed into a tire shape or a form which can be incorporated into a tire. Also the light emitting sheet may be used for a fabric, and a piece of clothing which emits light may be made with such a fabric. Furthermore, a light emitting doormat may be made.
According to another aspect of the invention, a light emitting sheet device is provided comprising a plurality of light emitting sheets according to the present invention by providing an electrically insulating separation layer between neighboring light emitting sheets. This may form an illumination system,
According to another aspect of the invention, a method of manufacturing a light emitting sheet provided with an embedded LED is provided, the LED having a light emitting body provided with a first terminal pin and a second terminal pin, comprising the steps of: providing a first layer mainly comprising an uncured translucent rubber containing electrically conductive particles; immersing the LED into the first layer such that the first terminal pin is at least partly immersed in and in electrical contact with the first layer; curing the first layer to form a first electrically conductive layer; providing a layer mainly comprising the uncured translucent rubber on top of the first electrically conductive layer; curing the layer mainly comprising an uncured translucent rubber to form a electrically insulating layer; providing a second layer mainly comprising the uncured translucent rubber containing the electrically conductive particles on top of the electrically insulating layer, such that the second terminal pin is at least partly immersed in and in electrical contact with the second layer; and curing the second layer to form a second electrically conductive layer.
According to a further embodiment of the invention, the method further comprises the steps of: prior to the step of providing the first layer, providing a bottom layer mainly comprising an uncured translucent rubber, and curing the bottom layer to form a bottom electrically insulating layer onto which the first layer is to be provided; and providing a top layer mainly comprising an uncured translucent rubber on top of the second electrically conductive layer, and curing the top layer to form the top electrically insulating layer. The invention further relates to a light emitting sheet mentioned above comprising further correspondingly embedded LEDs or a light emitting sheet manufactured by a method mentioned above comprising further correspondingly embedded LEDs.
It is noted that the invention relates to all possible combination of features recited in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the invention will be apparent from and elucidated with reference to the drawings in which:
Figure 1 schematically illustrates a cross sectional view of an embodiment of the light emitting sheet according to the invention;
Figure 2a-c schematically illustrate a cross sectional view of various embodiment of the light emitting sheet according to the invention;
Figure 3 schematically illustrates a cross sectional view of a further embodiment of the light emitting sheet according to the invention; Figure 4 schematically illustrates a cross sectional view of a further embodiment of the light emitting sheet according to the invention;
Figure 5 schematically illustrates in a perspective view an embodiment of the light emitting sheet according to the invention during operation;
Figure 6 schematically illustrates a cross sectional view of an embodiment of a tire comprising the light emitting sheet according to the invention during operation,
Figure 7a-e schematically illustrate an exemplary method of manufacturing the light emitting sheet according to the invention using translucent rubber. DETAILED DESCRIPTION OF EMBODIMENTS
It is noted that the same reference numbers have been used for corresponding elements in the embodiments whenever possible. Referring to Figure 1 , a schematic cross section of an embodiment of a light emitting sheet 100 according to the present invention is shown. A plurality of LEDs, of which an LED 10 is depicted, is embedded in the light emitting sheet 100. The light emitting sheet 100 comprises a first electrically conductive layer 20 having an outer surface 21 and an inner surface 22, a second electrically conductive layer 30 having an outer surface 31 and an inner surface 32 and an electrically insulating layer 40 provided between the inner surface 22 of the first electrically conductive layer 20 and the inner surface 32 of the second electrically conductive layer 31. The first terminal pin 12 and the second terminal pin 13 are embedded in the first and the second electrically conductive layer 20, 30, respectively. The light emitting body 11 of the LED 10 is embedded in the multilayer structure of the first electrically conductive layer 20, the electrically insulating layer 40 and the second electrically conductive layer 30.
The light emitting body 11 of the LED 10 has a first surface 11a having a portion closest to the outer surface 21 of the first electrically conductive layer 20 and a second surface 1 Ib having a portion closest to the outer surface 31 of the second electrically conductive layer 30. The LED 10 may be arranged to emit light from both the first and the second surface 1 Ia, 1 Ib, or also from other surfaces.
The multilayer structure constituted by the first electrically conductive layer 20, the electrically insulating layer 40 and the second electrically conductive layer 30 may be substantially translucent. The first and the second electrically conductive layer 20, 30 may mainly comprise a translucent rubber embedded with electrically conductive particles. The electrically insulating layer 40 may mainly comprise a translucent rubber. The rubber may be a natural rubber or a synthetic rubber. The translucent property of the multilayer structure allows the light from the first and the second surface 11a, 1 Ib to be emitted from both sides of the light emitting sheet 100. Alternatively, only one of the two electrically conductive layers 20, 30 may be substantially translucent. In this case, light will be emitted from only one side of the light emitting sheet 100.
Alternatively, only the portions of the multilayer structure between the first and/or the second surface 11a, 1 Ib and the outer surface 21, 31 of the first or the second electrically conductive layer 20, 30, respectively, may be substantially translucent. In a further embodiment, the electrically conductive layers 20 and 30 are patterned in order to make them partially translucent. For example, the conductive layer may have holes which are filled with a non-conductive, but translucent rubber. Referring to figure 2a-2c, various embodiments with the light emitting body
11 of the LED 10 positioned differently within the multilayer structure are disclosed.
In figure 2a, the first surface 11a of the light emitting body 11 coincides with the outer surface 21 of the first electrically conductive layer 20. In such an arrangement, the multilayer structure does not have to have a translucent portion for the light to be emitted from the outer surface 21 of the first electrically conductive layer.
In figure 2b, the light emitting body 11 is embedded in the electrically insulating layer 40. The terminal pins 12, 13 are also embedded in the electrically insulating layer 40, but are physically and electrically connected to the first and the second electrically conductive layer 20,30, respectively. In figure 2c, the light emitting body is fully encapsulated in the first electrically insulating layer 20 without contacting the electrically insulating layer 40. A second terminal pin 13 reaches the second electrically insulating layer 30 by penetrating through the first electrically conductive layer 20 with a first part and through the electrically insulating layer 40 with a second part. The first part is covered by an insulating cover 80 in order to ensure that the second terminal pin 13 does not make an electrical contact with the first electrically conductive layer 20. The insulating cover 80 may be made of the same material as the electrically insulating layers 20, 30.
Referring to figure 3, an LED is used where the light is emitted in a direction substantially parallel to the multilayer. In this embodiment, embedded light scattering particles 70 scatter the light, and light will be emitted out of the light emitting sheet. The light scattering particles may be e.g. TiO2, ZrO2 or MgO. The diameters of the light scattering particles may be e.g. 100 nm to 2μm. The amount of the light-scattering particles may be in a range of 0.01-2 %, preferably 0.01-0.5% by weight. The degree of scattering may be controlled by the amount of the scattering particles as well as the sizes of the scattering particles.
Referring to figure 4, the light emitting sheet 100 further comprises a bottom electrically insulating layer 50 provided on the outer surface 21 of the electrically conductive layer 20 and a top electrically insulating layer 60 provided on the outer surface 31 of the electrically conductive layer 30. The light emitting body 10 is embedded in the bottom layer 50. The LED may be arranged to emit light in a direction perpendicular to the multilayer structure. Similarly with the electrically conductive layers 20, 30, the bottom insulating layer 50 may be substantially translucent for the light to be emitted from the light emitting sheet 100. The top insulating layer 60 may be reflective. In this case, light transmitted through the multilayer to the top insulating layer 60 will be reflected and be emitted from the bottom electrically insulating layer 50.
Figure 5 schematically shows an embodiment of the light emitting sheet 100 according to the present invention, provided with a plurality of LEDs, during operation. The LEDs 10 emit light when the electrically conductive layers 20, 30 are connected to the power source. When the light emitting sheet is cut according to the dashed line A-A, the part of the light emitting sheet 100 no longer connected to the power source, shown in the left of the drawing, will stop emitting light. If this left part is contacted again to the part still connected to the power source, it will start to emit light again. Figure 6 schematically shows a cross sectional view of an embodiment of a tire comprising a light emitting sheet 100 according to the present invention. The light emitting sheet 100 can be formed into a round shape of a tire. As illustrated, the light can be emitted from the surface of the tire which contacts the ground. It will be appreciated that the light can be emitted in any direction by suitably arranging the structure of the tire. For example, light can be emitted from the side of the tire in a direction perpendicular to the surface of the tire which contacts the ground.
Figures 7a-e schematically illustrate an exemplary method of manufacturing the light emitting sheet according to the invention using a translucent rubber.
As illustrated in figure 7a, a first layer 20a of an uncured translucent rubber embedded with electrically conductive particles is applied on top of a bottom electrically insulating layer 50. While the first layer 20a is in a liquid form, an LED 10 is immersed into the first layer, as illustrated in figure 7b. The immersion is done in such a way that the first terminal pin 12 of the LED 50 is at least partly immersed in the first layer 20a. Subsequently the first layer 20a is cured to form a first electrically conductive layer 20, for example with vulcanization, or any other suitable means for curing the rubber.
After the first electrically conductive layer 20 is formed, a layer 40a of an uncured translucent rubber is applied on top of the first electrically conductive layer 22, as illustrated in figure 7c. Subsequently the layer 40a is cured to form an electrically insulating layer 40. After the electrically insulating layer 40 is formed, a layer 30a of an uncured translucent rubber embedded with electrically conductive particles is applied on top of the electrically insulating layer 40, as illustrated in figure 7d. The amount of the material of the layer 30a is selected so that the second terminal pin 13 is at least partly immersed in the second layer 30a. Subsequently the second layer 30a is cured to form a first electrically conductive layer 30.
As illustrated in figure 7e, another layer 60a of an uncured translucent rubber is applied on top of the second electrically conductive layer 30. Subsequently the layer 60a is cured to form a top electrically insulating layer 60. It is noted that the curing process of each of the layers may be performed in two or more steps. The layer may be partially cured before the subsequent layer is applied. In this case, the adhesion between the layers may be promoted. In such a case, full curing is carried out afterwards.
It is to be noted that the multilayer structure of the first and the second electrically conductive layers 20, 30 and the electrically insulating layer 40 may be made by the successive curing processes as described above, and electrically insulating layers 50, 60 may then be provided to sandwich the electrically conductive layers 20, 30. The electrically insulating layers 50, 60 may be adhered to the electrically conductive layers 20, 30.
Various modifications of the exemplary embodiments described above will be apparent to those skilled in the art.
In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb "comprise" and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. Especially, it will be appreciated that the light emitting sheet may comprise more than one LED. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Moreover it is noted that the term LED primarily means light emitting diode, but also includes, in this paper, any other optical- semiconductor element, such as laser diode.

Claims

CLAIMS:
1. A light emitting sheet (100) provided with an embedded LED (10), the sheet having a multilayer structure comprising: a first electrically conductive layer (20) and a second electrically conductive layer (30) and an electrically insulating layer (40) provided between the first electrically conductive layer and the second electrically conductive layer, wherein the LED has a light emitting body (11), a first terminal pin (12) and a second terminal pin (13), the first terminal pin and the second terminal pin being mechanically and electrically connected to the first and the second electrically conductive layer, respectively.
2. A light emitting sheet as claimed in claim 1, wherein the light emitting body of the LED is embedded in the multilayer structure, - the first electrically conductive layer (20) having an outer surface (21) and an inner surface (22), the second electrically conductive layer (30) having an outer surface (31) and an inner surface (32) and the electrically insulating layer (40) provided between the inner surface of the first electrically conductive layer and the inner surface of the second electrically conductive layer, - the multilayer structure being at least partly permeable to light for allowing transmission of light from the LED to at least one of the outer surface of the first electrically conductive layer and the outer surface of the second electrically conductive layer.
3. A light emitting sheet as claimed in claim 2, wherein the LED is arranged to emit light from a first surface (1 Ia) of the light emitting body, which first surface faces or lies in the outer surface of the first electrically conductive layer, and the multilayer structure has a substantially translucent portion between the first surface of the light emitting body and the outer surface of the first electrically conductive layer.
4. A light emitting sheet as claimed in claim 3, wherein the LED is arranged to emit light from a second surface (1 Ib) of the light emitting body, which second surface faces or lies in the outer surface of the second electrically conductive layer, and the multilayer structure has a substantially translucent portion between the second surface of the light emitting body and the outer surface of the second electrically conductive layer.
5. A light emitting sheet as claimed in any one of the claims 2 to 4, wherein the electrically insulating layer is substantially translucent and the light emitting body of the LED is embedded in the electrically insulating layer.
6. A light emitting sheet as claimed in claim 2, wherein the LED is arranged to emit light in a direction substantially parallel to the multilayer structure.
7. A light emitting sheet as claimed in any one of claims 1 to 6, wherein the light scattering particles (70) are embedded in the multilayer structure.
8. A light emitting sheet as claimed in claim 1, the multilayer structure further comprising: a bottom electrically insulating layer (50) provided on the outer surface of the first electrically conductive layer and a top electrically insulating layer (60) provided on the outer surface of the second electrically conductive layer, wherein the light emitting body of the LED is embedded in the multilayer structure, the multilayer structure being at least partly permeable to light for allowing transmission of the light from the LED to at least one of a surface of the bottom electrically insulating layer remote from the first electrically conductive layer and a surface of the top electrically insulating layer remote from the second electrically conductive layer.
9. A light emitting sheet as claimed in any one of the claims 1 to 8, wherein the electrically insulating layer between the first and the second electrically conductive layers mainly comprises a translucent rubber.
10. A light emitting sheet as claimed in any one of the claims 1 to 9, wherein the first and the second electrically conductive layers mainly comprise a translucent rubber with embedded electrically conductive particles.
11. A light emitting sheet as claimed in any one of the claims 1 to 10, further provided with embedded electronics for controlling the light output from each of the LEDs
12. An illumination system comprising a light emitting sheet as claimed in any one of the claims 1 to 11 and a power source connected or connectable to the first electrically conductive layer and the second electrically conductive layer.
13. A light emitting sheet device comprising a plurality of light emitting sheets as claimed in any one of the claims 1 to 10, wherein an electrically insulating separation layer is provided between neighboring light emitting sheets.
14. A method of manufacturing a light emitting sheet provided with an embedded LED (10), the LED having a light emitting body (11) provided with a first terminal pin (12) and a second terminal pin (13), comprising the steps of: providing a first layer (20a) mainly comprising an uncured translucent rubber containing electrically conductive particles; immersing the LED into the first layer such that the first terminal pin is at least partly immersed in and in electrical contact with the first layer; curing the first layer to form a first electrically conductive layer (20); providing a layer (40a) mainly comprising the uncured translucent rubber on top of the first electrically conductive layer; curing the layer mainly comprising an uncured translucent rubber to form an electrically insulating layer (40); providing a second layer (30a ) mainly comprising the uncured translucent rubber containing the electrically conductive particles on top of the electrically insulating layer, such that the second terminal pin is at least partly immersed in and in electrical contact with the second layer; and curing the second layer to form a second electrically conductive layer (30).
15. A method as claimed in claim 14, further comprising the steps of: prior to the step of providing the first layer, providing a bottom layer (50a) mainly comprising an uncured translucent rubber, and curing the bottom layer to form a bottom electrically insulating layer (50) onto which the first layer is to be provided; and providing a top layer (60a) mainly comprising an uncured translucent rubber on top of the second electrically conductive layer, and curing the top layer to form the top electrically insulating layer (60).
PCT/IB2009/050431 2008-02-08 2009-02-03 Light emitting sheet WO2009098636A1 (en)

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