Patent ID: 7024082

Claim:
A method for forming an optical converter comprising: forming a web of light guide ribbon structures by the steps of roll molding a web of substrate having a pattern of channels, each channel spaced apart from its adjacent channel in accordance with a predefined pattern, and coating an optical material into the channels on the web of substrate to form light guides; applying a coating to the web of light guide ribbon structures; segmenting the web of light guide ribbon structures to form individual light guide ribbon structures with each ribbon structure having an input edge and an output edge with light guides extending therebetween; and assembling the individual light guide ribbon structures in a stacked arrangement; wherein said coating applied to the light guide ribbon structures provides a spacer between adjacent stacked said light guide ribbon structures, wherein the optical converter has an input edge and an output edge and wherein the spacer is used to provide a separation between the light guide ribbon structures at the input edge that is different from the separation of light guide ribbon structures at the output edge.