AC/DC LED Integrated Current-Limiting Resistor Protection
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Solution Overview
Problem
High voltage AC/DC LEDs are prone to catastrophic failure due to broad variations in AC line voltages, which cause exponential increases in current, reducing their reliability and lifetime without suitable current limitations and protection.
Innovation Solution
Integration of current-limiting resistors or protection circuits directly on the AC/DC LED chip, in the lamp package, or on the submount, using semiconductor materials or externally deposited resistive materials to limit current and provide voltage surge protection, eliminating the need for separate surge protection circuitry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If AC/DC LEDs are directly powered by high voltage AC or DC without protection, then device simplicity is maintained, but reliability deteriorates due to catastrophic failure from voltage variations
Solution Approach 1:
The patent merges the protection function with the LED chip structure by integrating current-limiting resistors and protection circuits directly onto the chip or submount. This combining approach adds reliability while minimizing the increase in device complexity through unified design.
Solution Approach 2:
The LED device provides its own protection through integrated current-limiting resistors and protection circuits that are part of the device itself. This self-service approach eliminates the need for external protection components, improving reliability without proportionally increasing overall device complexity.
2Reliability
If current-limiting protection is integrated on the chip, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the protection function into modular components (current-limiting resistors, protection circuits) that can be independently fabricated and then integrated. This segmentation allows specialized fabrication processes for each component while maintaining overall manufacturing feasibility through standardized integration procedures.
Solution Approach 2:
The submount serves as an intermediary platform that facilitates the integration of current-limiting resistors and protection circuits with the LED chip. This mediator approach simplifies manufacturing by providing a standardized interface and assembly process between the chip and protection elements.
3Reliability
If discrete current limiting resistor chip is assembled in lamp package, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the discrete current-limiting resistor chip with the LED chip assembly within the lamp package, creating a unified protected LED unit. This merging approach improves reliability through added protection while minimizing assembly complexity through integrated packaging design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integrated protection mechanisms significantly enhance the reliability and durability of AC/DC LEDs by limiting current and protecting against voltage surges, allowing them to function reliably across varying line voltages without the need for additional surge protection, thus extending their lifespan and performance.
Implementation Method 1
a current-limiting resistor is monolithically integrated on the AC/DC LED chip
Implementation Method 2
Conventional LEDs, because of physical limitations, have traditionally only been run under very low DC voltages
Implementation Method 3
a passive protection circuit, which may include a resistor, a capacitor, a metal oxide varistor, a positive temperature coefficient ('PTC') thermistor
Implementation Method 4
a passive protection circuit, which may include a resistor, a capacitor, a metal oxide varistor, a positive temperature coefficient ('PTC') thermistor
Data Source
AI summary
A highly reliable, high voltage AC/DC LED device with integrated protection mechanism is disclosed. The protection element can be a current-limiting resistor, monolithically integrated on LED chip, or a discrete resistor assembled in the lamp package or submount. The protection elements may also include other parts integrated on a submount.