2D Closely Packed LED Array for Single-Shadow Color Mixing
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Solution Overview
Problem
Existing lighting fixtures using individual LED components with separate optical systems create multiple shadows due to separate color projections, unlike traditional incandescent fixtures which produce a single shadow.
Innovation Solution
A high power density LED array with closely spaced LED components, arranged in multiple color groups and powered by a unified optical system, utilizing a multi-layer PCB with high thermal conductivity and integrated LED driver for efficient heat management and color mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple individual LED components with separate optical systems are used, then color mixing capability is improved, but multiple shadows are created on the background
Solution Approach 1:
The patent combines multiple individual LED components of different colors into a single integrated array that shares a common optical system. Instead of having separate optical systems for each LED component, the invention merges them into one unified optical path, allowing all LED components to project through a single optical system and create only one shadow on the background, while still maintaining the ability to mix multiple colors.
2Power
If LED components are closely spaced to increase power density, then brightness and heat dissipation are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs a multi-layer PCB structure with through-holes to mount LED components, changing the mounting approach from surface mounting to vertical through-hole mounting. This parameter change in the mounting method allows for precise spacing control of closely packed LED components while maintaining manufacturing feasibility, as the through-hole structure provides built-in alignment and positioning reference.
3Object-generated harmful factors
If a unified optical system is used for the entire LED array, then single shadow projection is achieved, but optical power distribution becomes more difficult to control
Solution Approach 1:
The patent segments the LED array into multiple color groups (red, green, blue, white) with individually controllable LED components, while using a single unified optical system for the entire array. This segmentation at the LED component level allows independent control of each color group's power and intensity through separate circuitry, while the unified optical system ensures single shadow projection. The control complexity is managed by organizing LED components into color groups with dedicated driving circuits for each group.
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 solution provides a single shadow projection with improved color mixing and heat dissipation, enabling high brightness and extended LED life, while allowing individual control and dimming of each color group.
Implementation Method 1
a light-emitting diode (or LED) is a two-lead semiconductor light source comprising a p-n junction diode which emits light when activated. When a suitable voltage is applied to the leads, electrons recombine with electron holes within the device, releasing energy in the form of photons. This effect is called electroluminescence
Implementation Method 2
The LED array comprises a mounting substrate, a plurality of closely spaced LED components carried on the mounting substrate... utilizing a multi-layer PCB with high thermal conductivity and integrated LED driver for efficient heat management
Data Source
AI summary
An LED lighting fixture includes a housing, a substrate located within the housing, a plurality of LED groups of various colors mounted on the substrate, each LED color group including multiple LED components, at least one circuit communicating with a power supply and adapted for powering the LED components, and an optical component located at an output end of the housing. The LED components are arranged along first and second directions orthogonal to one another, such that no two LED of the same color reside adjacent one another along both of the first and second directions, and each LED component is spaced-apart from an adjacent LED component a distance no greater than 1.0 mm.