Patent ID: 8344397

Claim:
A lighting device comprising: a base substrate comprising a top surface and a bottom surface opposing the top surface; a plurality of snap-in features, the snap-in features being spaced apart from one another along first and second orthogonal dimensions of the base substrate, each snap-in feature of the plurality of snap-in features comprising a first surface, a second surface opposing the first surface, and a side surface, the second surface of the snap-in feature being in contact with the top surface of the base substrate; a plurality of cover substrates, each cover substrate of the plurality of cover substrates being elongated along the first dimension and comprising a rounded surface and a cover surface, at least a portion of the cover surface of the cover substrate being in contact with the top surface of the base substrate, and the rounded surface of the cover substrate having a rounded shape, wherein the cover surface of the cover substrate comprises a quantity of indentations, the indentations being spaced apart from one another and distributed along the first dimension, each of the indentations being shaped to conform with at least a portion of the side surface of the quantity of corresponding snap-in features, and wherein the cover substrate is disposed over the quantity of corresponding snap-in features, such that at least portions of the indentations are in contact with the at least a portion of the side surface of the quantity of corresponding snap-in features; a plurality of non-packaged light emitting diode (LED) dies, each non-packaged LED die being encapsulated between one of the plurality of snap-in features and a respective cover substrate of the plurality of cover substrates in a corresponding indentation of the cover surface of the respective cover substrate, such that during operation of the lighting device a peak intensity of light emitted by the non-packaged LED die is output through the rounded surface of the respective cover substrate; and a first set of conductors and a second set of conductors configured to provide power to the non-packaged LED dies, where the non-packaged LED dies are connected to the first set of conductors and the second set of conductors without wires, and the first set of conductors is formed, at least in part, on the first surface of the snap-in features and the second set of conductors is formed, at least in part, on the cover surface of the cover substrate, wherein at least a first portion of the first set of conductors are physically connected to at least a first portion of the second set of conductors.