Emitter Array Layout for Uniform Solid-State Lighting
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Solution Overview
Problem
Conventional solid state lighting (SSL) devices with uniform LED distributions suffer from non-uniform light intensity distribution, resulting in reduced quality, particularly with greater intensity at the center and less at the edges, leading to dark spots and inefficiencies.
Innovation Solution
The arrangement of SSL emitters with varying densities, spacing, sizes, and coverage area ratios in different regions of the emitter array, such as central and peripheral areas, to achieve a more uniform light output without the need for diffusion films, which reduce overall efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform LED distribution is used in SSL devices, then the device structure is simple and easy to manufacture, but the light intensity distribution becomes non-uniform with dark spots at edges
Solution Approach 1:
The patent applies local quality by varying the density, spacing, size, and coverage area ratio of SSL emitters in different regions of the emitter array. Specifically, the peripheral region has a higher emitter density with smaller spacing between emitters compared to the central region, while the central region emitters have larger sizes and higher coverage area ratios. This non-uniform distribution compensates for the natural light falloff at edges, achieving uniform light intensity distribution across the entire array without requiring diffusion films.
2Illumination intensity
If diffusion films are used to reduce non-uniformity, then light distribution uniformity improves, but overall light output and efficiency decrease
Solution Approach 1:
The patent extracts and eliminates the diffusion film component from the SSL device structure. Instead of using diffusion films to achieve uniform light distribution, the invention directly optimizes the emitter arrangement parameters (density, spacing, size, coverage area ratio) to produce uniform light output inherently. This removal of the diffusion film eliminates the associated light loss and efficiency reduction while maintaining uniformity through precise emitter positioning and sizing.
3Illumination intensity
If emitter density and spacing are optimized for uniformity, then light distribution quality improves, but device complexity increases
Solution Approach 1:
The patent segments the emitter array into distinct regions (central region and peripheral region) with different emitter configuration parameters. The central region emitters have larger sizes and higher coverage area ratios with greater spacing, while peripheral region emitters have smaller sizes and lower coverage area ratios with smaller spacing. This segmentation allows each region to be optimized independently for its specific light output requirements, achieving overall uniformity while maintaining manageable device complexity through regional rather than fully individual customization.
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
This approach results in a highly uniform light output across the array, reducing dark spots and maintaining high efficiency by optimizing emitter placement and spacing to ensure consistent illumination.
Implementation Method 1
the LED 4 emits blue light that stimulates the converter material 6 to emit light at a desired frequency
Implementation Method 2
depositing a converter material (e.g., a phosphor) on an LED... the converter material 6 to emit light at a desired frequency
Data Source
AI summary
Solid state lighting (SSL) devices and methods of manufacturing such devices. One embodiment of an SSL device comprises a support and an emitter array having a plurality of SSL emitters carried by the support. The emitter array has a central region and a peripheral region outward from the central region. Individual SSL emitters in both the central and the peripheral regions have a primary emission direction along which an intensity of light from the SSL emitters is highest, and the primary emission direction of the SSL emitters in the central region is at least substantially the same direction as the primary emission direction of the SSL emitters in the peripheral region. Additionally, a first coverage area ratio of the SSL emitters in the central region is different than a second coverage area ratio of the SSL emitters in the peripheral region.