Formation of phosphor regions for broad-area lighting systems

Abstract

In accordance with certain embodiments, phosphor arrangements are formed via adhering phosphors to activated regions on a substrate and transferring them to a different substrate.

What is claimed is: 
     
         1 .- 16 . (canceled) 
     
     
         17 . A roll-to-roll apparatus for fabricating phosphor arrangements, the apparatus comprising:
 a first roll for supplying a continuous length of a flexible substrate material;   a second roll for accepting the continuous length of flexible substrate material from the first roll;   a die-attach tool for attaching light-emitting elements to the flexible substrate material as the flexible substrate material travels from the first roll to the second roll;   a rotatable drum having a photoconductive surface and configured to dispose portions of phosphor over the flexible substrate material as the flexible substrate material travels from the first roll to the second roll;   disposed over at least a portion of the drum, a first dispenser for dispensing phosphor powder over the photoconductive surface; and   an illuminator for selectively illuminating portions of the photoconductive surface as the drum rotates to generate an electrostatic image on the photoconductive surface, regions of the electrostatic image being attractive to the dispensed phosphor powder,   wherein the second roll accepts flexible substrate material having light-emitting elements each with a phosphor portion disposed thereover.   
     
     
         18 . The apparatus of  claim 17 , further comprising, disposed between the die-attach tool and the drum, a second dispenser for dispensing a binder material over the light-emitting elements after attachment thereof to the flexible substrate material. 
     
     
         19 . The apparatus of  claim 17 , further comprising a scanning system for scanning light from the illuminator over the photoconductive surface. 
     
     
         20 . A roll-to-roll apparatus for fabricating phosphor arrangements, the apparatus comprising:
 a first roll for supplying a continuous length of a flexible substrate material;   a second roll for accepting the continuous length of flexible substrate material from the first roll;   a third roll for supplying a continuous length of a second substrate material;   a die-attach tool for attaching light-emitting elements to the second substrate material after the second substrate material is supplied by the third roll;   a rotatable drum having a photoconductive surface and configured to dispose portions of phosphor over the flexible substrate material as the flexible substrate material travels from the first roll to the second roll;   disposed over at least a portion of the drum, a first dispenser for dispensing phosphor powder over the photoconductive surface;   an illuminator for selectively illuminating portions of the photoconductive surface as the drum rotates to generate an electrostatic image on the photoconductive surface, regions of the electrostatic image being attractive to the dispensed phosphor powder; and   an arrangement of rollers configured to bring the second substrate material and the flexible substrate material in proximity at a joining location after (i) light-emitting elements have been attached to the second substrate material and (ii) phosphor portions have been disposed over the flexible substrate material, thereby enabling transfer of the light-emitting elements to the phosphor portions over the flexible substrate material,   wherein the second roll accepts flexible substrate material having light-emitting elements each with a phosphor portion disposed thereover.   
     
     
         21 . The apparatus of  claim 20 , further comprising, disposed between the drum and the joining location, a second dispenser for dispensing a binder material over the phosphor portions after disposal thereof over the flexible substrate material. 
     
     
         22 . The apparatus of  claim 20 , further comprising a scanning system for scanning light from the illuminator over the photoconductive surface. 
     
     
         23 . The apparatus of  claim 17 , wherein the regions of the electrostatic image attractive to the dispensed phosphor powder correspond to portions of the photoconductive surface illuminated by the illuminator. 
     
     
         24 . The apparatus of  claim 17 , wherein the regions of the electrostatic image attractive to the dispensed phosphor powder correspond to portions of the photoconductive surface not illuminated by the illuminator. 
     
     
         25 . The apparatus of  claim 17 , wherein the first dispenser comprises (i) a container for phosphor powder, and (ii) a roller disposed between the container and the drum. 
     
     
         26 . The apparatus of  claim 17 , wherein the illuminator comprises one or more lasers. 
     
     
         27 . The apparatus of  claim 17 , wherein the illuminator comprises one or more light-emitting diodes. 
     
     
         28 . The apparatus of  claim 17 , further comprising, disposed between the drum and the second roll, a heater for heating dispensed phosphor powder. 
     
     
         29 . The apparatus of  claim 17 , further comprising a cleaning mechanism for cleaning phosphor powder off of the drum. 
     
     
         30 . The apparatus of  claim 29 , wherein the cleaning mechanism comprises at least one of a brush or a blower. 
     
     
         31 . The apparatus of  claim 17 , further comprising phosphor powder disposed within the first dispenser. 
     
     
         32 . The apparatus of  claim 31 , wherein the phosphor powder is charged. 
     
     
         33 . The apparatus of  claim 31 , wherein the phosphor powder is mixed with magnetized carrier beads. 
     
     
         34 . The apparatus of  claim 18 , further comprising, disposed between the second dispenser and the second roll, a heater for heating dispensed binder material. 
     
     
         35 . The apparatus of  claim 20 , wherein the regions of the electrostatic image attractive to the dispensed phosphor powder correspond to portions of the photoconductive surface illuminated by the illuminator. 
     
     
         36 . The apparatus of  claim 20 , wherein the regions of the electrostatic image attractive to the dispensed phosphor powder correspond to portions of the photoconductive surface not illuminated by the illuminator. 
     
     
         37 . The apparatus of  claim 20 , wherein the first dispenser comprises (i) a container for phosphor powder, and (ii) a roller disposed between the container and the drum. 
     
     
         38 . The apparatus of  claim 20 , wherein the illuminator comprises one or more lasers. 
     
     
         39 . The apparatus of  claim 20 , wherein the illuminator comprises one or more light-emitting diodes. 
     
     
         40 . The apparatus of  claim 20 , further comprising, disposed between the drum and the second roll, a heater for heating dispensed phosphor powder. 
     
     
         41 . The apparatus of  claim 20 , further comprising a cleaning mechanism for cleaning phosphor powder off of the drum. 
     
     
         42 . The apparatus of  claim 41 , wherein the cleaning mechanism comprises at least one of a brush or a blower. 
     
     
         43 . The apparatus of  claim 20 , further comprising phosphor powder disposed within the first dispenser. 
     
     
         44 . The apparatus of  claim 43 , wherein the phosphor powder is charged. 
     
     
         45 . The apparatus of  claim 43 , wherein the phosphor powder is mixed with magnetized carrier beads. 
     
     
         46 . The apparatus of  claim 21 , further comprising, disposed between the second dispenser and the second roll, a heater for heating dispensed binder material.