This video shows a new process we are developing to laminate ultra thin LEDs between sheets of Polycarbonate. The first sheet in the video shows the LEDs between two sheets of 0.118" thick clear Polycarbonate. The second sheet shows the LEDs between a mirrored piece of 0.177" Polycarbonate and a piece of clear 0.118" Polycarbonate - the LEDs are only visible when they are lit as normally they are hidden by the mirror.
The next production trial will use a piece of light diffusing Polycarbonate as the front face in order to diffuse the LED light and prevent "hotspots". We also plan to increase the density of the LEDs. We also plan to use thinner Polycarbonate to make the whole structure 0.118" thick in total.
Conventional lamination methods would damage LEDs, but a new technique that we are working on is making these type of products possible. The technique would allow very bright, low weight signs or lighting powered by only a 9 volt supply.