Dual color flexible light source, systems and methods of manufacture

Abstract

Lighting devices, systems and method of manufacture are described here. A lighting device includes at least one substrate and at least one pair of diodes on the at least one substrate. A first and second diode in each of the pairs are electrically coupled together in an antiparallel configuration. At least the first diode in each of the pairs is an LED. The lighting device also includes at least two electrical contact lines, which may power at least the first diode in each of the pairs via a drive current. The first diode in each of the pairs is powered on by the drive current forward biasing the first diode and reverse biasing the second diode and is powered off by the drive current reverse biasing the first diode and forward biasing the second diode.

Description

DUAL COLOR FLEXIBLE LIGHT SOURCE, SYSTEMS AND METHODS OF MANUFACTURECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 526,319, filed July 12 2023, the contents of which are incorporated herein by reference.BACKGROUND

[0002] Technologies in the automotive industry have trended to slim, strip-like lighting solutions, both for interior and exterior lighting functions. New styling solutions for car interior and exterior illumination (e.g., white light strips for daytime running lamps (DRL) and position lighting, amber light strips for signaling, and red light strips for stop / tail functions) continue to be sought after. In addition, new styling solutions are sought for car interior and exterior illumination purposes. For example, contour lines and roof rail illumination are becoming popular as well as illumination of the grill area, which is not functional for electric cars. A rising trend for such technologies is the use of homogeneous line emitters or “coins.”SUMMARY

[0003] Lighting devices, systems and method of manufacture are described herein. A lighting device includes at least one substrate and at least one pair of diodes on the at least one substrate. A first and second diode in each of the pairs are electrically coupled together in an antiparallel configuration. At least the first diode in each of the pairs is an LED. The lighting device also includes at least two electrical contact lines, which may power at least the first diode in each of the pairs via a drive current. The first diode in each of the pairs is powered on by the drive current forward biasing the first diode and reverse biasing the second diode and is powered off by reverse biasing the first diode and forward biasing the second diode.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] A more detailed understanding can be had from the following description, given by way of example in conjunction with the accompanying drawings wherein:

[0005] FIG. 1A is a diagram showing build-ups of a flexible foil printed circuit board (PCB) that provide S-wires between interposers;

[0006] FIG. 1 B is a cross-sectional view of the flexible foil PCB of FIG. 1 A showing one interposer and one LED on the interposer;

[0007] FIG. 2A is a diagram of another example flexible foil PCB;

[0008] FIG. 2B is a circuit diagram of an example circuit for electrically coupling, controlling and driving LEDs of the flexible foil PCB of FIG. 1 A, 1 B, or 2A;

[0009] FIG. 3 is a circuit diagram of an example circuit 300 for electrically coupling, controlling and driving LEDs of the flexible foil PCB of FIG. 1 A, 1 B, 2A or 2B;

[0010] FIGs. 4A, 4B, 4C, 4D, and 4E are circuit diagrams showing different electrical contacting schemes for the example circuit of FIG. 3;

[0011] FIGs. 5A and 5B are circuit diagrams showing example circuits for electrically coupling, controlling and driving LEDs of the flexible foil PCB of FIG. 1 A, 1 B, 2Aor 2B where the first and second diode in each diode pair are disposed on separate interposers lands;

[0012] FIG. 6 is a circuit diagram showing seven pairs of LEDs according to the scheme illustrated in FIG. 3A or 3B, each electrically coupled to an electrical contact line;

[0013] FIG. 7 is a circuit diagram of an example circuit for electrically coupling, controlling and driving LEDs of the flexible foil PCB of FIG. 1 A, 1 B, 2A or 2B where the second diode in each pair is not an LED;

[0014] FIG. 8 is a circuit diagram showing five (5) groups of LED / diode pairs according to the scheme illustrated in FIG. 7, each electrically coupled to an electrical contact line;

[0015] FIG. 9 is a circuit diagram showing seven (7) groups of LED / diode pairs according to the scheme illustrated in FIG. 7, each electrically coupled to an electrical contact line;

[0016] FIG. 10 is a flow diagram of an example method of manufacturing a lighting device according to any of the embodiments described herein; and

[0017] FIG. 11 is a flow diagram of an example method of manufacturing an automotive lighting system according to any of the embodiments described herein.DETAILED DESCRIPTION

[0018] Examples of different light illumination systems and / or light emitting diode (“LED”) implementations will be described more fully hereinafter with reference to the accompanying drawings. These examples are not mutually exclusive, and features found in one example may be combined with features found in one or more other examples to achieve additional implementations. Accordingly, it will be understood that the examples shown in the accompanying drawings are provided forillustrative purposes only and they are not intended to limit the disclosure in any way. Like numbers refer to like elements throughout.

[0019] It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms may be used to distinguish one element from another. For example, a first element may be termed a second element and a second element may be termed a first element without departing from the scope of the present invention. As used herein, the term "and / or" may include any and all combinations of one or more of the associated listed items.

[0020] It will be understood that when an element such as a layer, region, or substrate is referred to as being "on" or extending "onto" another element, it may be directly on or extend directly onto the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" or extending "directly onto" another element, there may be no intervening elements present. It will also be understood that when an element is referred to as being "connected" or "coupled" to another element, it may be directly connected or coupled to the other element and / or connected or coupled to the other element via one or more intervening elements. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present between the element and the other element. It will be understood that these terms are intended to encompass different orientations of the element in addition to any orientation depicted in the figures.

[0021] Relative terms such as "below," "above," "upper,", "lower," "horizontal" or "vertical" may be used herein to describe a relationship of one element, layer, or region to another element, layer, or region as illustrated in the figures. It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.

[0022] Conventional lighting strips may be impeded by their cost structure due to a complex buildup of individual wires connecting interposer boards to form an electrical circuit. In this regard, the cost structure may require expensive components that are individually assembled by an expensive surface mounting technology (“SMT”) assembly process, with a multitude of solder joints in one homogeneous line emitter. In addition, because wires are mounted on a backside of an interposer board of the homogeneous line emitter and light emitting diodes (“LEDs”) are mounted on a frontside of the interposer board, this may result in a homogeneous line emitter that is rather thick. Additionally, conventional lighting strips may lack real three-dimensional (3D) flexibility and an inability to withstand harsh automotive use conditions due to larger dimensions found in conventional technologies with or without integration into silicone. Such conventional lighting strips are also typically limited to a single color, typically white, which is not ideal for automotive applications, which may benefit from, at least,red and amber colors, in addition to white, to fulfill the many different and growing lighting functions in the vehicle.

[0023] Embodiments described herein provide for a flexible automotive grade light source. Generally, the flexible automotive grade light source is a more cost-effective light source that can be small in size, have a high flexibility, have a high light flux, have a high homogeneity, and include automotive grade robustness with inexpensive components. Embodiments described herein further enable such light source to have multi-color function, as described in detail below.

[0024] By way of example, the flexible automotive grade light source can utilize a specially shaped flexible foil printed circuit board assembly (PCBA) build-up including a flexible 3D LED light source. In embodiments, the flexible foil PCBA can be a thin film flexible foil PCBA. The specially shaped flexible foil PCBA may replace wires and interposers of conventional technologies. The specially shaped flexible foil PCBA may include electrical connection schemes where two or three electrical contact lines are provided per metal layer that enable multiple electrical contact lines in a vertical stack of metal layers. For example, two metal layers with two electrical contact lines each may enable four electrical contact lines that allow more flexibility to electrically connect the flexible 3D LED light source compared to conventional technologies. In conventional technologies, for example, the number of electrical contact lines may be limited to three due to space availability. Additionally, the two or three electrical contact lines per metal layer can include segments (e.g., three or more bends, such as five (5) bends or semi-circles / half-sines segments) constructed to withstand automotive reliability requirements. Embodiments where four or more electrical contact lines are provided via multiple metal layers enable individual addressing of segments of LEDs in the strips as well as multi-color functionality, as described in detail below.

[0025] FIG. 1A is a diagram showing build-ups of a flexible foil PCB 101 and 102 that provide S- wires (e.g., in the area 1 10) between interposers 120. According to one or more embodiments, using a specially shaped flexible foil PCB build-up, a flexible 3D LED light source can be created where the flexible foil PCB may replace the wires and interposers carrying LEDs of conventional technologies.

[0026] In the examples illustrated in FIG. 1A, the flexible foil PCB 101 , 102 can be constructed such that an area 1 10 between interposers 120 on which the LEDs are placed may include any number of curved shapes to mimic, for example, winding river, serpentine or snake-like, parabolic, ellipsoidal, and / or sinusoidal shapes. The interposers 120 can be of any shape, such as rectangular or an irregular shape, and can be configured to receive a placement of SMT components (e.g., LEDs, microcontrollers, etc.). As mentioned above, the area 1 10 may include multiple stacked metal layers, which may each include multiple electrical contact lines. The interposers 120 may be lands in themetal layers in embodiments. In some embodiments, the metal layers and electrical contact lines may be formed from copper.

[0027] By way of example, a circular-sinusoidally shaped area 110 can include at least three sections 131 , 132, and 135. The two outermost sections 131 and 135 terminate into the interposers 120. As shown in FIG. 1A, quarter circles or half sines may be drawn into and integrated in the interposers 120. According to one or more embodiments, a circular-sinusoidally shaped area 110 can include five sections 131 , 132, 133, 134, and 135, with the interior sections 132, 133, and 134 being half circular or half sinusoidal shapes. By way of example, each section 131 , 132, 133, 134, and 135 can be horizontally flipped relative to the previous or next section (e.g., a shifted mirror of an adjacent section). According to one or more embodiments, the five sections 131 , 132, 133, 134, and 135 can have a lower amplitude at a height of the interposers 120.

[0028] According to one or more embodiments, the at least three sections 131 , 132, and 135 can be characterized by an outer border line (e.g., an outer border of the bent segments), an inner border line (e.g., an inner border of the bent segments), and two straight lines connecting the ends of the two border lines in the shortest way. These straight lines are helping lines only where the at least three sections 131 , 132, and 135 are joined together. The inner border line of the outermost semi- circles / half-sines thereby continues to follow the half circular shape, with the consequence that the outermost half sines 131 and 135 form a quarter sine transitioning into a quarter circle. The inner border line at the end of the half circle then transfers into a spiral with opposite curvature as compared to the quarter circle within the interposer. In border cases, the spiral can become another semi-circle. By this the edge that would have formed on the interposer is cut away. The top border line of the semi- circle / half-sine ends at the edge of the interposer, transitioning smoothly from the half circular / sinusoidal section to the straight interposer upper border. Altogether, the flexible foil PCBA shape minimizes a stress build-up during thermal cycling to a point that the PCBA can be reliably embedded into the silicone matrix to form the desired light source and meeting automotive reliability requirements.

[0029] The flexible foil PCBA can be constructed such that areas 150 between interposers 160 on which LEDs 170 are placed (also referred to herein as LED lands) include any number of curved shapes to mimic winding river, serpentine or snake-like, parabolic, ellipsoidal, and / or sinusoidal shapes. According to one or more embodiments, outermost bent second area segments may be partially integrated into first area lands. Further, an inner border line of the segment continues into the first area land to form a semi-circle, followed by a spiral of an opposite turning direction to connect the integrated segments inner border line with the outer side of the land. Furthermore, an outer borderline of the first half of the outermost segment in a similar manner partly continues into the land and connects the segment border to the land border in a half circular or swinging curve.

[0030] According to one or more embodiments, each flexible automotive grade light source may include the PCBA embedded in a silicone matrix, that provides a light source with homogeneous high flux light output. Further, each flexible automotive grade light source may be (e.g., each 3D LED product) mechanically flexible, bi-axially bendable, and capable to meet the high automotive reliability requirements. Further, each flexible automotive grade light source may be integrated directly as a shapeable line or combined with a suitable optical element to create an elongated light surface. According to one or more embodiments, each flexible automotive grade light source can include animation by segmenting. Segmenting can include an ability to turn on and off individual segments independent of the others, as is required in signaling or animated welcome light functions. Individual segments may correspond to different colors of light, as described in detail below.

[0031] According to one or more embodiments, the flexible automotive grade light source can be constructed with a height selected from a range of 0.01 cm to 1.1 cm (e.g., 8 mm); a width selected from a range of 0.01 cm to 1 .0 cm (e.g., 6 mm); a light emitting area width selected from a range of 0.01 cm to 1.1 cm (e.g., 8 mm); a total length selected from a range of 1 cm to 500 cm (e.g., 10 cm or 100 cm). By way of example, the flexible automotive grade light source can be an 8 x 8 mm2 elongated (up to 50 cm) light source with homogeneous high flux light output. The flexible automotive grade light source can provide a maximal allowable LED to LED pitch, and hence an oscillation of a wavy structure can be defined by a thickness of the thin light source. By way of example, a 22 mm LED to LED pitch can be used for 8 mm height to still preserve a homogeneity of the light emitted while reducing the components required per total length to the minimum. By way of another example, larger distance pitches of the flexible automotive grade light source are easier to manufacture compared to a wired approach of conventional technologies. In this regard, a maximum pitch can be dependent on a size of a mixing box of the flexible automotive grade light source. For instance, the flexible automotive grade light source (e.g., a 3D LED size of 6 x 8 mm2) can estimate a maximum LED to LED pitch of 22 mm when a homogeneous light output shall be maintained.

[0032] According to one or more embodiments, the flexible automotive grade light source can include a light source with a light emitting area length comparable to the total length, a light source that is flexible in three dimensions, and a light source with a homogeneous light output from the light emitting surface. According to one or more embodiments, the flexible automotive grade light source can include a light source that can be illuminated at once (e.g., providing static illumination), a light source that can be illuminated in segments (e.g., providing dynamic illumination), and a light source that withstands automotive reliability requirements.

[0033] FIG. 1 B is a cross-sectional view of the flexible foil PCB of FIG. 1 A showing one interposer 154 and one LED 153 on the interposer 154. In the example illustrated in FIG. 1 B, the LED 153 on the interposer 154 is placed in an opening in a whitebox 159. One metal layer 158 is illustrated, which includes three electrical contact lines 155, 156 and 157. As is discussed in detail herein, multiple layers (e.g., up to 4 metal layers or possibly more) may be stacked in a vertical stack, each including one or more (e.g., up to three) electrical contact lines per metal layer. The whitebox 159 is filled with one or more silicone materials. A transparent silicone may fill the space below the interposer in the whitebox. One or more layers 152 of silicone may fill space above the LED in the whitebox, and a diffusor 151 may be placed on top. The diffusor may have a maximum thickness w.

[0034] In embodiments, the whitebox 159 may be formed from a silicone matrix, which can withstand automotive grade reliability requirements. According to one or more embodiments, the silicone matrix can include a white reflecting H-shaped outer optical mixing box, where a connecting horizontal bar of the H is asymmetrically drawn to a bottom of the H. Further, the flexible foil PCBA is placed into a first cavity of the H and rectangular holes that are punched into the connecting horizontal bar of the H receive the LEDs connected by the flexible foil PCBA to shine into a second cavity of the H. The first cavity can be smaller than the second cavity. Also, both cavities can be filled with clear silicone, where the clear silicone may have a wavy surface structure on a top side that is filled and covered with diffusing silicone. The diffusing silicone can be characterized in that the maximum diffusor thickness w of the wavy structure is placed above the LEDs while a minimum diffusor thickness spot is placed in between the LEDs. Additional round holes can be added in the connecting horizontal bar of the H to allow silicone diffusion through the bar during vacuum processing, which may, for example, help removing air bubbles in the flexible automotive grade light sources. Further, rectangular holes receiving the LEDs can be elongated towards the walls of an outer box to ease silicone diffusion through the connecting horizontal bar of the H during vacuum processing. In some embodiments, a space between interposers may correspond to the maximum diffusor thickness.

[0035] FIG. 2A is a diagram of another example flexible foil PCB 200. According to one or more embodiments, the flexible foil PCB 200 can be one piece. According to one or more embodiments, the flexible foil PCB 200 can be embedded in a silicone matrix. In the example illustrated in FIG. 2A, the flexible foil PCB 200 includes a first land 201 , a second land 202, and a flexible foil area 203.

[0036] The first and second lands 201 and 202 can include a first section 213, a second section 215, and a third section 217. The first and second lands 201 and 202 can include conductive portions 221 and 222. The first and second lands 201 and 202 can include electrical vias to connect the conductive portions 221 and 222 to any surface of the flexible foil PCB.

[0037] The first and second lands 201 and 202 can be any shape, such as rectangular or an irregular shape. The first and second lands 201 and 202 can be configured to receive, with respect to the conductive portions 221 and 222, a placement of SMT components (e.g., LEDs, microcontrollers, etc.). According to one or more embodiments, one or multiple LEDs can be present on a first side of the first and second lands 201 and 202. According to one or more embodiments, at least one connecting structure can be present on at least one of a second side of the first and second lands 201 and 202 to enable an electrical connection of the one or multiple LEDs to a power source.

[0038] According to one or more embodiments, the first section 213 can be rectangular or square lands for the placement of SMT components. The second and third sections 215 and 217 can protrude from the first section 213. A shape of the second and third sections 215 can correspond to a shape of the flexible foil area 203 (e.g., irregular shapes of the lands can include protruding sections that match the outermost ends of the flex foil area). One or more technical effects, benefits, or advantages of the shape of the second and third sections 215 corresponding to the shape of the flex foil area 203 includes eliminating electrical interference, electromagnetic interference, radio-frequency interference, electromagnetic induction, electrostatic coupling, or the like. Further, an outer border 225 can define or characterize the first and second lands 201 and 202. The outer border 225 can include a non-conductive material.

[0039] The flexible foil area 203 can be a portion of the flexible foil PCB substrate between the first and second lands 201 and 202 (pairs of the two or more lands). The flexible foil area 203 can include multiple metal layers, such as multiple copper layers. Each layer can contain electrical contact lines to form an electrical circuit with the first and second lands 201 and 202. For instance, the flexible foil area 203 can include a first conductive material 231 and a second conductive material 232 that correspondingly connect the conductive portions of the first and second lands 201 and 202. The flexible foil area 203 can include electrical vias to connect the electrical contact lines to any surface of the flexible foil area 203. The flexible foil area 203 can include any number of curved shapes to mimic winding river, serpentine or snake-like, parabolic, ellipsoidal, and / or sinusoidal shapes.

[0040] According to one or more embodiments, the flexible foil area 203 may include sinusoidal formed bends (e.g., the bends substantially follow a half-sine path). According to one or more embodiments, the flexible foil area 203 includes semi-circular formed bends or semi-elliptical formed bends (e.g., the bends substantially follow a semi-circle path or a semi-elliptical path). For instance, the flexible foil area 203 can include at least three (3) semi-circular bends, such as five (5), to withstand automotive reliability requirements (e.g., in low voltage automotive lighting applications).

[0041] According to one or more embodiments, the flexible foil area 203 includes parabolic formed bends (e.g., the bends substantially follow a parabolic curved path). For instance, the flexible foil area203 can include three (3) parabolic formed bends to withstand automotive reliability requirements (e.g., in low voltage automotive lighting applications). According to one or more embodiments, the flexible foil area 203 includes a combination of sinusoidal formed bends, semi-circular formed bends, semi-elliptical formed bends, and parabolic formed bends.

[0042] By way of example, the flexible foil area 203 can include three bent segments connecting the lands 201 and 202 (though not limited thereto). In the example illustrated in FIG. 2A, the flexible foil area 203 includes three bent segments 261 , 262, and 263 (i.e., curved or bent portions of the flexible foil area 203). Further, the flexible foil area 203 can define or be characterized by outer borders 265 and 266 and an inner border 267 of the bent segments. The outer borders 365 and 366 and the inner border 267 can include a non-conductive material.

[0043] The bent segments 261 (e.g., an outermost bent area segment) can be partially integrated into the first land 201 . The bent segments 263 (e.g., an outermost bent area segment) can be partially integrated into the second land 202. The inner border 267 of the flexible foil area 203 continues into the first and second lands 201 and 202. According to one or more embodiments, and as shown in FIG. 2, the flexible foil area 203 can curve into the first and second lands 201 and 202 (e.g., swing around substantially mirroring the half-sine or parabolic path) at an angle of 35-40 degrees to form a bay 280 or like opening Thus, the outer borders 265 and 266 continue as the outer boards 225 of the first and second lands 201 and 202. One or more technical effects, benefits, or advantages of the shape of the bay 280 with respect to the second and third sections 215 may include eliminating electrical interference, electromagnetic interference, radio-frequency interference, electromagnetic induction, electrostatic coupling, or the like.

[0044] FIG. 2B is a diagram of another example flexible foil PCB 300 (e.g., parabolic shaped thin film flexible foil PCBA) according to one or more embodiments. According to one or more embodiments, the flexible foil PCB 300 can be one piece. According to one or more embodiments, the flexible foil PCB 300 can be embedded in a silicone matrix.

[0045] FIG. 2B depicts a repeating pattern and can incorporate the properties of the flexible foil PCB substrate 300, as described herein. The flexible foil PCB substrate 300 can be used in low voltage automotive lighting applications. The flexible foil PCB 300 may include multiple lands 310, multiple flexible foil areas 320, and multiple bays 430. The flexible foil areas 320 utilize parabolic shapes. According to one or more embodiments, the flexible foil areas 320 can include an amplitude that is less than or equal to a height of the lands 310. One or more technical effects, benefits, or advantages of the structure of the example flexible foil PCB substrate 300 includes decreasing an LED to LED pitch with respect to the lands 310 from greater than 20 mm to at or lower than 20 mm, such as 12 mm or lower.

[0046] According to one or more embodiments, adjacent segments of the flexible foil areas 320 can mirror (along a length of the flexible foil PCB substrate 300) neighboring segments joined at lines connecting ends of inner and outer borders, such as in shortest manner. By way of example, outermost bent area segments of the flex foil areas 320 can be partially integrated into adjacent lands 310, such that inner borders continue into the adjacent lands 310 by swinging around to substantially mirror a half-sine or parabolic line at an angle of 35-40 degrees and forming a bay like opening. By way of further example, integrating the outermost bent area segments of the flexible foil areas 320 into adjacent lands 310 can include bringing / continuing outer borders of the flexible foil areas 320 to outer borders of the lands 310, which is followed by a spiral of opposite turning direction to connect the integrated segments inner border line with the outer side of the land (as shown in FIGS. 2 and 3). The outer borders of the flexible foil areas 320 smoothly transition into top and bottom outer borders of the lands 320, respectively.

[0047] According to one or more embodiments, a connecting structure can be present on a second side or a backside of one of the outermost land 310a or 31 Oe (of the plurality of lands 310). According to one or more embodiments, two or more connecting structures can be present on second sides of one or more of the two outermost lands 310a or 310e (of the plurality of lands 310). According to one or more embodiments, a connecting structure can be present on a second side of the flexible foil PCB in between two outermost lands 310a or 31 Oe (of the plurality of lands 310). According to one or more embodiments, a connecting structure can be present on a second side of interior lands 310b, 310c, or 31 Od (of the plurality of lands 310). According to one or more embodiments, a connecting structure can be present on a second side of the flexible foil PCB substrate in between any of the plurality of lands 310. According to one or more embodiments, the connecting structure contains a rigid PCB mounted on the backside of an interposer or a land, to which the connecting structure is attached.

[0048] FIG. 3 is a circuit diagram of an example circuit 300 for electrically coupling, controlling and driving LEDs of the flexible foil PCB of FIG. 1A, 1 B, 2A or 2B. The circuit 300 may form, or be part of, a lighting device, which may be coupled to an external control and / or power bus 318 of a vehicle to form an automotive lighting system. In the example illustrated in FIG. 3, multiple interposers or lands 310 are spaced apart from one another along a horizontal direction 301. While nine (9) interposers / lands 310 are illustrated in FIG. 3, the circuit can be formed from as little as two (2) interposers / lands or many more than nine (9) within the scope of the embodiments described herein. A pair of diodes, including a first LED 302 and a second LED 304 may be provided on each of the interposers / lands 310.

[0049] The first and second LEDs 302 / 304 on each of the interposers / lands 310 may be spaced apart from each other in a direction perpendicular to the horizontal direction 301 (represented by thearrow 305 in FIG. 3). It has been found that the homogeneity of the light emitted by the lighting device is strongly dependent on the position of the LEDs along in the horizontal direction 301 but remains unchanged by a shift perpendicular to the horizontal direction. The enables the placement of two LEDs on one interposer / land and, thus, multi-color operation of the lighting device. In embodiments, the first and second LED 302 / 304 on each interposer / land 310 may be spaced apart in the perpendicular direction 301 equidistant from imaginary line running through the lighting device in the horizontal direction 301 (not shown in FIG. 3). In embodiments, the first LEDs 302 may be configured to emit light having a first color when powered on, and the second LEDs 304 may be configured to emit light having a second color, different from the first color, when powered on, allowing the lighting device to illuminate a light-emitting area of the lighting device with two colors mutually independently.

[0050] While the embodiments are described herein relative to the flexible foil PCB of FIGs. 1 A, 1 B, 2A and 2B, the circuit 300, and all other circuits described herein, can be used with other substrates. For example, all of the LEDs can be placed on one substrate, such as a rigid PCB. Alternatively, the LEDs can be placed on multiple interposers / lands as shown in FIG. 3, and the interposers can be rigid PCB interposers or flexible PCB lands, connected by electrical contact lines, which may be wavy or have a different shape.

[0051] In the example illustrated in FIG. 3, the pairs of LEDs may be electrically coupled together in an antiparallel configuration. At least one electrical contact line may be used to drive the LEDs in opposite directions to, for example, power on all of the first LEDs while powering off all of the second LEDs, and vice versa. In this way, a current in one direction my illuminate LEDs having one color of light emission while the reversed current direction may illuminate the LEDs having the second color of light emission. By using a pulse width modulated (PWM) current, intermediate colors between the two colors of light emission may be generated in dependence on the ratio of the pulses in the two directions.

[0052] In the example illustrated in FIG. 3, three electrical contact lines 306, 308 and 312 are provided, which may have the wavy or other shapes described above Groups of the pairs of LEDs may be electrically coupled together in series via the electrical contact line 312. For example, as shown in FIG. 3, three pairs of LEDs may be coupled together in series via the electrical contact line 312, and each of the groups of six (6) LEDs may be electrically coupled to both the electrical contact line 306 and the electrical contact line 308. The electrical contacts lines 306 and 308 may be an anode contact line or a cathode contact line, respectively.

[0053] Taking advantage of the flexible foil PCB described above with respect to FIGs. 1A, 1 B, 2A and / or 2B, in the example illustrated in FIG. 3, the three (3) electrical contact lines 306, 308 and 312 may be provided in two vertically stacked metal layers (not shown in FIG. 3 but described in theembodiments above) or may be provided in a single layer. The control circuitry 316 may control and power on the first LEDs 302 in each pair independently of the second LEDs 304 in each pair, using an external power supply and the electrical contact line 306 and / or 308.

[0054] As mentioned, the electrical contact lines, such as the electrical contact lines 306, 308 and 312 illustrated in FIG. 3, may be provided in multiple, vertically stacked metal layers. Each metal layer can contain up to three (3) electrical contact lines. In the example illustrated in FIG. 3, for simplicity of design and electrical connection, it may be desirable to place the anode and / or cathode line(s) (i.e., electrical contact lines 306, 308) in a buried or bottom one of the metal layers below the LED that may be electrically coupled to solder pads of the LED by vias. An example where three buried electrical contact lines in the same layer below the LEDs are used to control and drive the LEDs on a flexible foil PCB is shown in FIG. 1 B (see electrical contact lines 155, 156, 157). The electrical contact lines in different layers may be at least partially electrically coupled by vias.

[0055] In some embodiments, the controller may be an internal controller and may be disposed on a backside of the interposer opposite from the side on which the LEDs are disposed. The controller may thereby be connected to one or more of the buried electrical contact lines (e.g., the electrical contact lines in the bottom metal layer of the vertical stack) and electrically coupled to the first, second and potentially third LEDs to actuate them independently in groups. While in some embodiments, the controller may be on the bottom side of the interposer / land, it may be on the top side as well in some embodiments. Each interposer / land may include one or more controllers, one or more controllers may be disposed on one interposer / land in a group to control the entire group together, or one or more controllers may be disposed on at least two interposers / lands in a group for control of the entire group. As described above, in some embodiments, the controller may be configured to drive the LEDs in a PWM mode to generate a combined color.

[0056] In the example illustrated in FIG. 3, each group of pairs of LEDs 302 and 304 includes three (3) pairs of LEDs and a total of six (6) LEDs. However, one of ordinary skill in the art will recognize that more or less LEDs can be included in a group consistent with the embodiments described herein. In some embodiments, the LEDs in series may be balanced by at least one resistor per group of LEDs, generating a static light source where all groups are connected in parallel, and all LEDs of one color may be illuminated together. In other embodiments, groups of LED pairs may be independently addressable, without a balancing resistor, allowing for generation of dynamic light effects when the groups of LEDs in series of one color are illuminated independently of each other.

[0057] FIGs. 4A, 4B, 4C, 4D, and 4E are circuit diagrams showing different electrical contacting schemes for the example circuit of FIG. 3. In each of the drawings, 418 represents groups of the LEDs illustrated in FIG. 3 and described above. In FIG. 4A, LEDs with opposing LED polarity anddifferent colors are driven by two contact areas allowing three (3) mutually independent dynamic segments or groups having two (2) colors each. In FIG. 4B, LEDs with opposing LED polarity and different colors are driven by one (1) contact area allowing two (2) independent dynamic segments or groups having two (2) colors each. In FIG. 4C, LEDs with opposing LED polarity and different colors are driven by two (2) contact areas allowing four (4) independent dynamic segments or groups having two (2) colors each. In FIG. 4D, LEDs with opposing LED polarity and different colors are driven by two (2) contact areas allowing seven (7) dynamic segments or groups having two (2) colors each. In FIG. 4E, LEDs with opposing LED polarity and different colors are driven by two (2) contact areas allowing m independent dynamic segments or groups having two (2) colors each. The embodiments illustrated in FIGs. 4D and 4E may provide for maximum usage of the metal layers.

[0058] The multiple LEDs on each interposer / land may be separate LED packages or single, multicolor LED packages. In both cases, the LEDs can be powered independently of each other using the electrical circuitry described with respect to FIGs. 3, 4A, 4B, 4C, 4D and / or 4E. The different color LEDs of each pair may be protected by a transient voltage suppression (TVS) diode. While two colors of LEDs are shown in FIG. 3, in embodiments, such as illustrated in FIGs. 4A, 4B, 40, 4D and 4E, more than two LED colors, such as three colors, are possible. The LEDs may be turned on mutually independently, or in groups, generating a two to three function lighting device (as described in more detail below).

[0059] In the embodiments described herein, the light-emitting area of the first and second LEDs may be kept small, such as the size of a LUXEON Versat 2020 or smaller. For a dual color LED, the size may also be kept small, such as the size of a LUXEON Versat DT 3535 dual color or smaller. In some embodiments, neighboring pairs of LEDs may have alternating color sequences, whereas in other embodiments, neighboring pairs of LEDs may have the same color sequence.

[0060] FIGs. 5A and 5B are circuit diagrams showing example circuits for electrically coupling, controlling and driving LEDs of the flexible foil FOB of FIG. 1 A, 1 B, 2Aor 2B where the first and second diode in each diode pair are disposed on separate interposers lands. In FIG. 5A, a first circuit 500 is shown where both LEDs in the LED pair 318 are disposed on one interposer / land 310 and control of powering on and off each of the LEDs in the pair 318 individually may be effected via a single electrical contact line by reversing the current through the line. A second circuit 550 is also shown where the first LED 502 and the second LED 504 in the pair are provided on separate interposers / lands 510, and, similar to the first circuit, control of powering on and off each of the LEDs in the pair individually may be effected via a single electrical contact line by reversing the current through the line. The pairs of LEDs may have the same color.

[0061] Similar to the example illustrated in FIG. 3, in the circuit 550 illustrated in FIG. 5A, the pairs of LEDs may be electrically coupled together in an antiparallel configuration. One electrical contact line may be used to drive the LEDs in opposite directions to, for example, power on the first LED while powering off the second LED, and vice versa. In this way, a current in one direction my illuminate LEDs having one color of light emission while the reversed current direction may illuminate the LEDs having the second color of light emission. By using a pulse width modulated (PWM) current, intermediate colors between the two colors of light emission may be generated in dependence on the ratio of the pulses in the two directions.

[0062] In the example illustrated in FIG. 5B, the first and second LEDs 502 and 504 are divided into groups 503 and 507. In the illustrated example, half of the LEDs (e.g., the first LEDs 502) are in the first group 503 and the other half of the LEDs (e.g., the second LEDs 504) are in the second group 507. The first LEDs 502 are electrically coupled in series on a first electrical contact line 512. The second LEDs 504 are electrically coupled antiparallel to the first LEDs 502 in series on a second electrical contact line 514. Each of the groups 503, 507 is electrically coupled to a common anode or cathode line 516. While not shown in FIG. 5B, each group of LEDs pairs may be individually connected to another electrical contact line that can be powered, together with the common anode or cathode line 516, from external, to light the LEDs using a PWM signal. This is shown in FIG. 6 and may enable an elongated light source where neighboring halves of LED pairs form segments of the elongated light source that may be illuminated mutually independently from the other segments in the light source by the PWM signals. Thereby the light source may be dynamically illuminated by turning on and off the segments. Such light source may also withstand automotive reliably requirements, as described in more detail above.

[0063] FIG. 6 is a circuit diagram showing seven pairs of LEDs 503 each electrically coupled to a common anode or cathode line 602. Each pair of LEDs 503 is individually coupled to another electrical contact line 604, 606, 608, 610, 612, 614 or 618, respectively. Given the number of electrical contact lines required to drive each LED pair or segment, in some embodiments, the number of LEDs may be limited to fourteen (14) or seven (7) pairs, which can be accommodated using eight (8) electrical contact lines in three (3) metal layers, as described above. In some embodiments, a lighting device may consist of just one LED pair or segment, which may significantly reduce the number of electrical contact lines required for individually driving the lights, and may enable them to be driven without use of a controller.

[0064] The circuits illustrated in FIGs. 5A, 5B and 6 may form, or be part of, a lighting device, which may be coupled to an external control and / or power bus of a vehicle to form an automotive lighting system, similar to the embodiment described above with respect to FIGs. 3 and 4 (although not shownin FIGs. 5A, 5B and 6 for simplicity). In the example illustrated in FIG. 5B, multiple interposers or lands 510 are spaced apart from one another along a horizontal direction 501 . While six (6) interposers / lands 510 are illustrated in FIG. 5B, the circuit can be formed from as little as two (2) interposers / lands (as shown in FIG. 5A, for example) or many more than six (6) within the scope of the embodiments described herein.

[0065] In the example illustrated in FIG. 5B, three electrical contact lines 512, 514 and 516 are provided (and a fourth electrically coupled to each individual pair as shown in FIG. 6), which may have the wavy or other shapes described above, where extending between interposers 510. Taking advantage of the flexible foil PCB described above with respect to FIGs. 1A, 1 B, 2A and 2B, in the example illustrated in FIG. 5B, the electrical contact lines may be provided in two vertically stacked metal layers (not shown in FIG. 5B but described in the embodiments above). The control circuitry (not shown in FIG. 5B) may control and power on the first LEDs 502 independently of the second LEDs 504, using an external power supply and the electrical contact line (not shown in FIG. 5B).

[0066] As mentioned, the electrical contact lines may be provided in multiple, vertically stacked metal layers. Each metal layer can contain up to three (3) electrical contacts. In the example illustrated in FIG. 5B, for simplicity of design and electrical connection, it may be desirable to place the common anode or cathode line 516 in a buried or bottom one of the metal layers below the LED that may be electrically coupled to solder pads of the LED by vias. An example where three buried electrical contacts line in the same layer below the LEDs are used to control and drive the LEDs on a flexible foil PCB is shown in FIG. 1 B (see electrical contact lines 155, 156, 157). The electrical contact lines in different layers may be at least partially electrically coupled by vias.

[0067] In some embodiments, the controller may be an internal controller and may be disposed on a backside of the interposer opposite from the side on which the LEDs are disposed. The controller may thereby be connected to one or more of the buried electrical contact lines (e.g., the electrical contact lines in the bottom metal layer of the vertical stack) and electrically coupled to the first, second and potentially third LEDs to actuate them independently in groups. While in some embodiments, the controller may be on the bottom side of the interposer / land, it may be on the top side as well in some embodiments. Each interposer / land may include one or more controllers, one or more controllers may be disposed on one interposer / land in a group to control the entire group together, or one or more controllers may be disposed on at least two interposers / lands in a group for control of the entire group. As described above, in some embodiments, the controller may be configured to drive the LEDs in a PWM mode to generate a combined color.

[0068] In the example illustrated in FIG. 5B, each group of LEDs 502 and 507 includes three (3) LEDs. However, one of ordinary skill in the art will recognize that more or less LEDs can be includedin a group consistent with the embodiments described herein. In some embodiments, the LEDs in series may be protected by at least one TVS diode.

[0069] When two electrical connectors are used, the lighting device may be limited such as to LEDs driven as described herein. Limiting the LEDs to one LED pair per group may enable a lighting device with single addressable LEDs without use of a controller.

[0070] The LEDs that are electrically coupled together in series may in some embodiments comply with European extra low voltage (ELV) directive requirements (e.g . , U < 48 volts).

[0071] In some embodiments, the second LEDs may not be LEDs but may be diodes. LED / diode pairs may be disposed on one or more substrates, such as described above with respect to FIG. 3.

[0072] FIG. 7 is a circuit diagram of an example circuit for electrically coupling, controlling and driving LEDs of the flexible foil PCB of FIG. 1 A, 1 B, 2A or 2B where the second diode in each pair is not an LED. In the example illustrated in FIG. 7, two groups of LED / diode pairs 752A, 752B are shown. The first group of LED / diode pairs 752A includes four (4) LED / diode pairs 750A, each including a first diode 702A, which is an LED, and a second diode 704A, which is not an LED. The second group of LED / diode pairs 752B includes four (4) LED / diode pairs 750B, each including a first diode 702B, which is an LED, and a second diode 704B, which is not an LED. While two (2) groups of four (4) LED / diode pairs each are illustrated in FIG. 7, one of ordinary skill in the art will recognize that different numbers of groups and different numbers of LED / diode pairs per group may be used consistent with the embodiments described herein. By way of example, an embodiment including five (5) groups of LED / diode pairs is described below with respect to FIG. 8 and an embodiment including seven (7) groups of LED / diode pairs is described below with respect to FIG. 9. In some embodiments, each LED may be protected by a TVS diode.

[0073] Within each of the diode pairs 750, the first diode / LED 702 is electrically coupled antiparallel to the corresponding second diode 704. The LED / diode pairs in the first group 752A may have a reverse through direction to the LED / pairs in the second group 752B, as shown in FIG. 7. For even numbers of LED / diode pairs 750, as illustrated in FIG. 7, the total number of LEDs in a lighting device can be halved . By arranging the pairs with their LED / diode antiparallel to each other, and half of the diode pairs with an opposite through direction to the other half of the diode pairs, the two halves of the LEDs in the LED / diode pairs can be mutually individually driven by one PWM signal such that a positive signal powers on half of the LEDs while a signal in the opposite direction powers on the other half of the LEDs.

[0074] FIG. 8 is a circuit diagram showing five (5) groups 752 of LED / diode pairs 750 each electrically coupled to a common anode or cathode line 810. Each group 752 of LED / diode pairs 750 is individually coupled to another electrical contact line 806, 808, 810, 812, 814, respectively, forindividual control of the LEDs in the groups, as described above. The through directions of the LEDs in each group may be as represented in the circuit diagram in FIG. 7.

[0075] FIG. 9 is a circuit diagram showing seven (7) groups 752 of LED / diode pairs 750 each electrically coupled to a common anode or cathode line 902. Each group 752 of LED / diode pairs 750 is individually coupled to another electrical contact line 904, 906, 908, 910, 912, 914 or 916, respectively, for individual control of the LEDs in the groups, as described above. The through directions of the LEDs in each group may alternate, as represented in FIG. 7 or 8.

[0076] The circuit illustrated in FIG. 7, 8 or 9 may form, or be part of, a lighting device, which may be coupled to an external control and / or power bus of a vehicle to form an automotive lighting system, similar to the embodiment described above with respect to FIG. 3 (although not shown in FIGs. 5A, 5B and 6 for simplicity). Where an embodiment, such as illustrated in FIG, 7, 8 or 9, is used with the flexible foil PCB of FIG. 1 A, 1 B, 2A or 2B, each LED / diode pair 750 may be provided on each of the interposers / lands.

[0077] The first and second diodes 702 / 704 on each of the interposers / lands may be spaced apart from each other in a direction perpendicular to the horizontal direction (not labeled in FIG. 7). It has been found that the homogeneity of the light emitted by the lighting device is strongly dependent on the position of the LEDs along in the horizontal direction but remains unchanged by a shift perpendicular to the horizontal direction. The enables the placement of two diodes next to each other on one interposer / land and, thus, multi-color operation of the lighting device. In embodiments, the first and second diode 702 / 704 on each interposer / land may be spaced apart in the perpendicular direction equidistant from an imaginary line running through the lighting device in the horizontal direction (not shown in FIG. 7). In embodiments, the first LEDs 702A in the first group 750A may be configured to emit light having a first color when powered on, and the first LEDs 702B in the second group 750B may be configured to emit light having a second color, different from the first color, when powered on, allowing the lighting device to illuminate a light-emitting area of the lighting device with two colors mutually independently

[0078] While the embodiments are described herein relative to the flexible foil PCB of FIGs. 1A, 1 B, 2A and 2B, the circuit illustrated in FIGs. 7, 8 and 9, and all other circuits described herein, can be used with other substrates. For example, all of the LED / diode pairs can be placed on one substrate, such as a rigid PCB. Alternatively, the LED / diode pairs can be placed on multiple interposers / lands as shown in FIG. 3, and the interposers can be rigid PCB interposers or flexible PCB lands, connected by electrical contact lines, which may be wavy or have a different shape.

[0079] In the example illustrated in FIG. 8, six (6) electrical contact lines are provided. In the example illustrated in FIG. 9, eight (8) electrical contact lines are provided. These electrical contactlines may have the wavy or other shapes described above where extending between interposers. Taking advantage of the flexible foil PCS described above with respect to FIGs. 1 A, 1 B, 2A and 2B, in the example illustrated in FIG. 8, the electrical contact lines may be provided in two or three vertically stacked metal layers (not shown in FIG. 8 but described in the embodiments above). In the example illustrated in FIG. 9, the electrical contact lines may be provided in three vertically stacked metal layers (not shown in FIG. 9 but described in the embodiments above). The control circuitry (not shown in FIGs. 7, 8 or 9) may control and power on the LEDs in each group individually, using an external power supply (not shown in FIGs. 7, 8 or 9) and the electrical contact line.

[0080] As mentioned, the electrical contact lines may be provided in multiple, vertically stacked metal layers. Each metal layer can contain up to three (3) electrical contacts. In the example illustrated in FIG. 7, 8 or 9, for simplicity of design and electrical connection, it may be desirable to place the common anode or cathode line in a buried or bottom one of the metal layers below the LED that may be electrically coupled to solder pads of the LED by vias. An example where three buried electrical contact lines in the same layer below the LEDs are used to control and drive the LEDs on a flexible foil PCB is shown in FIG. 1 B (see electrical contact lines 155, 156, 157). The electrical contact lines in different layers may be at least partially electrically coupled by vias.

[0081] In some embodiments, the controller may be an internal controller and may be disposed on a backside of the interposer opposite from the side on which the LEDs are disposed. The controller may thereby be connected to one or more of the buried electrical contact lines (e.g., the electrical contact lines in the bottom metal layer of the vertical stack) and electrically coupled to the first, second and potentially third LEDs to actuate them independently in groups. While in some embodiments, the controller may be on the bottom side of the interposer / land, it may be on the top side as well in some embodiments. Each interposer / land may include one or more controllers, one or more controllers may be disposed on one interposer / land in a group to control the entire group together, or one or more controllers may be disposed on at least two interposers / lands in a group for control of the entire group. As described above, in some embodiments, the controller may be configured to drive the LEDs in a PWM mode to generate a combined output light color. In some embodiments, the controller may be an internal controller and may be disposed on a backside of the interposer opposite from the side on which the LEDs are disposed. The controller may thereby be connected to one or more of the buried electrical contact lines (e.g., the electrical contact lines in the bottom metal layer of the vertical stack) and electrically coupled to the first, second and potentially third LEDs to actuate them independently in groups. While in some embodiments, the controller may be on the bottom side of the interposer / land, it may be on the top side as well in some embodiments. Each interposer / land may include one or more controllers, one or more controllers may be disposed on one interposer / land in agroup to control the entire group together, or one or more controllers may be disposed on at least two interposers / lands in a group for control of the entire group. As described above, in some embodiments, the controller may be configured to drive the LEDs in a PWM mode to generate a combined color.

[0082] In some embodiments, the two groups may be placed alternating. In some embodiments, LEDs electrically coupled together in series may comply with ELV directive requirements (e.g., U < 48 volts).

[0083] Given the number of electrical contact lines required to drive each LED pair or segment, in some embodiments, such as illustrated in FIG. 9, the number of groups or segments may be limited to fourteen, which can be accommodated using eight (8) electrical contact lines in three (3) metal layers, as described above. In some embodiments, a lighting device may consist of just one LED in any series connection, which may significantly reduce the number of electrical contact lines required for individually driving the lights, and may enable them to be driven without use of a controller.

[0084] The individual addressability of groups of different color LEDs may be extremely useful for a number of different automotive lighting functions. For example, such lights could be used for a combination of DRL and / or a position light with a turn signal. Additionally or alternatively, such lights could be used for a combination of a position light with a turn signal. Additionally or alternatively, such lights could be used for a combination of a stop and / or tail light with a turn signal.

[0085] For a combination of a DRL and / or position signal with a turn signal, for example, two LED colors could be used, such as Economic Commission for Europe (ECE) color box white and ECE color box amber, to generate the independent functions. For a combination of a stop and / or tail signal and a turn signal, for example, two LED colors could be used, such as ECE color box red and ECE color box amber, to generate the independent functions. In some embodiments, the two LED colors could be warm and cold white or cyan and green. In some embodiments, the two colors could be chosen from cyan, Economic Commission for Europe (ECE) White, cold white, warm white, SAE yellow / ECE amber, or ECE red. Where three LED colors are used, the three colors could be red, green and blue, although other colors are possible. In such embodiments, intermediate colors could be generated by mixing the light output of the multiple LED colors driven using PWM where the ratio of pulses per direction may define the total color output of the lighting device. Similarly, for a two color LED, the two colors could be chosen as cyan, cool white, warm white, amber or red, and intermediate colors could be generated by mixing the light output of the LEDs as described above.

[0086] In addition to the automotive lighting functions described above, the embodiments described herein may also be extremely useful for other functions, such as swiping signaling or animated welcome light functions. For such functionality, the lighting devices described herein may createanimation by segmenting the light source with the ability to turn on and off individual segments independent of others. Additionally, although the flexible foil PCB and circuitry are described herein relative to an automotive lighting system, one of ordinary skill in the art will understand that the technology can equally be applied to other lighting applications where independent control of multiple colored LEDs and / or a mixed output LED color is desirable, such as a luminaire for general lighting purposes, or a strip light for automotive or other decorative lighting. In some embodiments, any of the lighting devices described herein may be luminaires.

[0087] FIG. 10 is a flow diagram 1000 of an example method of manufacturing a lighting device according to any of the embodiments described herein. In the example illustrated in FIG. 10, the method includes obtaining at least one PCBA (1002). The PCBA may include at least one substrate and at least one pair of diodes on the at least one substrate. A first and second diode in each of the pairs may be electrically coupled together in an antiparallel configuration, and at least the first diode in each of the pairs may be an LED. The at least one pair of diodes on the PCBA may be electrically coupled to at least an anode line or a cathode line (1004) to power at least the first diode in each of the pairs via a drive current. The first diode in each of the pairs may be powered on by the drive current forward biasing the first diode and reverse biasing the second diode and may be powered off by reverse biasing the first diode and forward biasing the second diode.

[0088] FIG. 1 1 is a flow diagram 1100 of an example method of manufacturing an automotive lighting system according to any of the embodiments described herein. In the example illustrated in FIG. 11 , the method may include obtaining at least one lighting device (1102). The lighting device may include at least one substrate and at least one pair of diodes on the at least one substrate. A first and second diode in each of the pairs may be electrically coupled together in an antiparallel configuration. At least the first diode in each of the pairs may be an LED. The lighting device may also include at least an anode line or a cathode line, which may provide power to at least the first diode in each of the pairs via a drive current. The first diode in each of the pairs may be powered on by the drive current forward biasing the first diode and reverse biasing the second diode and may be powered off by reverse biasing the first diode and forward biasing the second diode. The lighting device may be electrically coupled to at least one of a communication or control bus of an automobile (1104).

[0089] As would be apparent to one skilled in the relevant art, based on the description herein, embodiments of the present invention can be designed in software using a hardware description language (HDL) such as, for example, Verilog or VHDL. The HDL-design can model the behavior of an electronic system, where the design can be synthesized and ultimately fabricated into a hardware device. In addition, the HDL-design can be stored in a computer product and loaded into a computer system prior to hardware manufacture.

[0090] Having described the embodiments in detail, those skilled in the art will appreciate that, given the present description, modifications may be made to the embodiments described herein without departing from the spirit of the inventive concept. Therefore, it is not intended that the scope of the invention be limited to the specific embodiments illustrated and described.

Claims

CLAIMSWhat is claimed is:

1. A lighting device comprising: at least one substrate; at least one electrical contact line, at least one pair of diodes on the at least one substrate within the at least one electrical contact line, a first diode and a second diode in each of the pairs being electrically coupled together in an antiparallel configuration, and at least the first diode in each of the pairs being a light-emitting diode (LED); and at least a first part of the at least one electrical contact line being electrically coupled to one side of the at least one pair of diodes and a second part of the at least one electrical contact line being electrically coupled to the other side of the at least one pair of diodes to power the first diode in each of the pairs via a drive current, whereby the first diode in each of the pairs is powered on by the drive current forward biasing the first diode and reverse biasing the second diode and powered off by the drive current reverse biasing the first diode and forward biasing the second diode.

2. The lighting device of claim 1 , wherein the second diode in each of the pairs is not an LED.

3. The lighting device of claim 2, wherein all of the first diodes are configured to emit light having the same color when powered on.

4. The lighting device of claim 2, wherein a first set of the first diodes is configured to emit light having a first color when powered on, and a second set of the first diodes is configured to emit lighting having a second color different from the first color when powered on.

5. The lighting device of claim 1 , wherein the second diode in each of the pairs is an LED.

6. The lighting device of claim 5, wherein all of the first and second diodes are configured to emit light having the same color when powered on.

7. The lighting device of claim 5, wherein the first diodes are configured to emit light having a first color when powered on, and the second diodes are configured to emit light having a second color different from the first color when powered on.

8. The lighting device of any one of claims 1 -7, wherein the at least one substrate is a rigid printed circuit board (PCB) interposer.

9. The lighting device of any one of claims 1-8, wherein all of the pairs of diodes are on the same substrate.

10. The lighting device of any one of claims 1 -8, wherein each of the pairs of diodes is on a separate substrate.11 . The lighting device of any one of claims 1-8, wherein the first and second diode in each of the pairs is on a separate substrate.

12. The lighting device of any one of claims 9-1 1 , wherein the separate substrates are spaced apart from one another in a horizontal direction, and the first and second diode in each pair are separated from one another perpendicular to the horizontal direction.

13. The lighting device of claim 12, wherein the lighting device is embedded in a polymer.

14. The lighting device of claim 12, further comprising a diffusing polymer over the circuit, the diffusing polymer having a maximum and a minimum, diffusor thickness, whereby a distance between maxima of the diffusor thickness corresponds to the distance between the LEDs of the same color.15.The lighting device of claim 12 or 13 wherein the maximum thickness of the diffusor corresponds to the distance between the LEDs of the same color.

16. The lighting device of any one of claims 1 -14, wherein the at least one substrate comprises a plurality of interposers connected by wavy-shaped wires, wherein the wavy-shaped wires are a plurality of electrical contact lines electrically coupled to at least two electrical contact lines to power the diodes17. The lighting device of any one of claims 1-14, wherein the at least one substrate comprises a plurality of PCB lands connected by a plurality of wavy-shaped thin metal films and at least one electrical contact line included in the plurality of wavy-shaped thin metal films, wherein the plurality of wavy-shaped thin metal films are isolated from one another by a polymer to form a flexible foil PCB assembly (PCBA).

18. The lighting device of claim 16 or 17, wherein the plurality of interposers are rigid PCB interposers.

19. The lighting device of claim 16 or 17, wherein the plurality of interposers are flexible PCB lands.

20. The lighting device of any one of claims 10-19, wherein pairs of diodes on the interposers or lands are connected in a group-.

21. The lighting device of any one of claims 10-19, wherein pairs of diodes on the interposers or lands are connected in a plurality of groups that are connected in series.

22. The lighting device of any one of claims 10-19, wherein pairs of diodes on the interposers or lands are connected in a plurality of groups that are individually drivable, wherein at least: a first group comprises LEDs configured to emit light having a first color when powered on and a second group comprises LEDs configured to emit light having a second color when powered on.

23. The lighting device of any one of claims 1-22, wherein the lighting device is embedded in silicone.

24. The lighting device of any one of claims 1-23, wherein the at least one pair of diodes is electrically and communicatively coupled to at least one internal or external controller and at least one internal or external driver, whereby the first and second diodes are driven by a pulse width modulated (PWM) signal to drive the first diodes and the second diodes in series individually with a positive or negative part of the PWM signal.

25. The lighting device of any one of claims 4-24, wherein intermediate colors are generated by mixing the light output of the diodes by driving them in a PWM mode, wherein a ratio of pulses per direction defines a combined color of the lighting device.

26. The lighting device of any one of claims 4-25, wherein the first color and the second color are one of cyan, Economic Commission for Europe (ECE) White, cold white, warm white, SAE yellow / ECE amber, or ECE red.

27. The lighting device of any one of claims 4-21 , wherein the first color and the second color are ECE color box white and ECE color box amber.

28. A luminaire comprising the lighting device of any one of claims 1 -27.

29. An automotive lighting system comprising the lighting device of any one of claims 1 - 27.

30. A method of manufacturing a lighting device comprising: obtaining at least one printed circuit board assembly (PCBA) comprising: at least one substrate, at least one pair of diodes on the at least one substrate, a first and second diode in each of the pairs being electrically coupled together in an antiparallel configuration, and at least the first diode in each of the pairs being a light-emitting diode (LED), and electrically coupling the at least one pair of diodes to at least a-first electrical line and a second electrical line to power at least the first diode in each of the pairs via a drive current, whereby the first diode in each of the pairs is powered on by the drive current forward biasing the first diode and reverse biasing the second diode and powered off by reverse biasing the first diode and forward biasing the second diode.

31. A method of manufacturing an automotive lighting system, the method comprising: obtaining a lighting device comprising: at least one substrate, at least one pair of diodes on the at least one substrate, a first and second diode in each of the pairs being electrically coupled together in an antiparallel configuration, and at least the first diode in each of the pairs being a light-emitting diode (LED), andat least an anode line and a cathode line configured to power at least the first diode in each of the pairs via a drive current, whereby the first diode in each of the pairs is powered on by the drive current forward biasing the first diode and reverse biasing the second diode and powered off by reverse biasing the first diode and forward biasing the second diode; and electrically coupling the lighting device to at least one of a communication or control bus of an automobile.

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