Patent ID: 8198109

Claim:
A method of forming a light emitting structure, the method comprising: providing a first layer having a first conductor pattern formed thereon; providing a plurality of non-packaged light emitting diode (LED) dies, each of the plurality of non-packaged LED dies having at least a corresponding first die electrode and a second die electrode; bonding the first die electrode of each of the non-packaged LED dies to the first conductor pattern on the first layer without wire bonds, such that the plurality of non-packaged LED dies are spaced apart from one another; disposing a light-transmissive sheet over the plurality of spaced-apart non-packaged LED dies, the sheet being formed of a dielectric material, such that the sheet deforms to conform to the plurality of spaced-apart non-packaged LED dies and contacts the first conductor pattern on the first layer between the plurality of spaced-apart non-packaged LED dies to separately encapsulate each of the plurality of non-packaged LED dies; forming first openings in the sheet over the second die electrode of each of the plurality of spaced-apart non-packaged LED dies and second openings in the sheet over portions of the first conductor pattern where the first layer is in contact with the first conductor pattern; forming a conductor layer overlying the sheet, such that the conductor layer is in electrical contact with the second die electrode of each of the plurality of spaced-apart non-packaged LED dies through the first openings and with the first conductor pattern through the second openings; and patterning the conductor layer to connect at least a group of the plurality of spaced-apart non-packaged LED dies in series.