A flexible module design with LED chips based on the PET-copper foils

The study focus on the process of metal electroplating on copper substrate to assemble LED chips and molding PET-copper foil to implement a flexible module with LED chips. The process can be divided into two parts,-assembling process and molding process. The LEDs are integrated on copper foil which can deal with the heat dissipation problem effectively. The metal electroplating on copper circuitry can achieve a soldered bonding to LED chips. The flexible layers of polyethylene terephthalate (PET)-copper foil are formed by two approaches-hot lamination and transfer molding. The thickness of PET-copper foil is an important parameter to the thermal design. A finite model is developed to study the effects of heat dissipation at different thickness of PET-copper foils. The results show that the flexible have a good thermal property with the thickness of PET-copper foil from 450um to 650um. Finally, a flexible model is simulated at temperature distribution with 5×5 LEDs.