Meter-scale large area LED-embedded light fabric for the application of fabric ceilings in rooms

We have developed a meter-scale light emitting diode (LED)-embedded light fabric and its weaving machine for application to a light device for fabric ceilings, which have recently become desired for lightweight safe ceilings in Japan and other countries with frequent earthquakes. The LED fabric structure is 1.2-m-wide woven fabric that has 5-mm-wide LED chip-mounted printed circuit board (PCB) tapes as wefts. LEDs are mounted on the tape of PCBs with a reel-to-reel chip mounting system. Then, the LED-mounted tapes are woven with a developed automatic looming machine that aligns the weft with an accuracy of 0.9 mm, which is suitable for precise arrangement of LEDs and wiring to power supply. A 1.2 × 1.2 m LED-embedded light fabric weighing 320 g/m² was woven. The luminance of the LED fabric is 353 lx at a distance of 1 m, which is the luminance of conventional office lighting. The temperature increase of LEDs without a rigid cooling aluminum plate is only 5.8 °C, and the LED fabric is flexible enough to sustain 1,000 bends down to a radius of 3 mm. This LED fabric and its weaving technology will lead to light devices that have lightweight, large area, and high flexibility for fabric ceilings, walls, and other large areas in homes and offices.