Abstract: A method and appartus for directly laminating a first conductive or insulating layer to a second insulating layer includes electron beam irradiation through the first layer to the interface between the first layer and the second layer. The electron beam irradiation bonds the two layers together without an adhesive or other intermediate layer. The method and apparatus utilizes an electron beam exposure system in a soft vacuum environment. Heat from the electron beam irradiation or from a separate heating element accelerates and increases the lamination of the first and second layers.

Abstract: High brightness LEDs are mounted directly on a heat pipe or are mounted on a substrate, which is mounted on the heat pipe. The heat pipe can be a common electrode for the LEDs mounted on the heat pipe. Multiple heat pipes can be arranged so that the LED arrays form a light recycling cavity to emit and reflect light. The resulting illumination system produces a higher brightness and higher total flux than any one of the individual LEDs making up the light source.