Flat LED Lamp High Density Surface Mount Array
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Solution Overview
Problem
Industrial lighting solutions require high-contrast, low-glare, and uniform illumination with high luminous intensity and color temperature, while existing LED-based solutions suffer from glare, shadowing, and insufficient light intensity due to punctiform light sources and limitations in minimum height.
Innovation Solution
A flat lamp design featuring a high LED arrangement density of at least 1 LED per 2.5 cm² over 250 cm² on a printed circuit board, using surface-mount LEDs without protruding lens parts, and passive or active control to maintain consistent forward voltage and color temperature, resulting in a surface luminous element that minimizes glare and shadows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If punctiform LED light sources are used, then the lamp can be made flat with low overall height, but glare effects and shadow formation occur
Solution Approach 1:
The patent divides the light source into multiple individual LEDs (at least 10, preferably 20-50) arranged in a linear array within the flat lamp housing. This segmentation of the punctiform light source into multiple discrete elements distributed across the lamp body allows the light to be emitted from multiple points simultaneously, reducing the intensity concentration that causes glare and shadow while maintaining the flat profile of the lamp.
2Illumination intensity
If high-power LEDs are used to increase light intensity, then luminous output improves, but minimum lamp height increases due to LED thickness
Solution Approach 1:
The patent combines multiple LEDs (each providing a portion of the required light output) into a single linear array within the flat lamp housing. By merging the light output of multiple smaller LEDs rather than relying on a single high-power LED, the patent achieves high luminous intensity while maintaining the thin profile of individual LEDs, thus avoiding the minimum height constraint imposed by thick high-power LEDs.
3Object-generated harmful factors
If LED arrangement density is increased to reduce glare, then uniform illumination improves, but manufacturing complexity increases
Solution Approach 1:
The patent specifies a particular arrangement density parameter for the LEDs (at least 1 LED per 2.5 cm² over an area of at least 250 cm²) to achieve uniform illumination. By establishing this specific parameter threshold, the patent provides a clear design guideline that balances illumination quality with manufacturing feasibility, avoiding the need for excessively high densities that would complicate manufacturing while still achieving the desired uniform light distribution.
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 cost-effective, high-contrast, low-glare, and high-intensity light with uniform distribution, avoiding shadows and irregularities, and extends the service life of LEDs by maintaining tight tolerances on LED performance parameters.
Implementation Method 1
EP 1082426 A2 discloses an areally radiating plate-shaped lighting unit which is realized by means of a circuit board on which light-emitting diodes are arranged to generate light
Data Source
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AI summary
The flat light has a lighting unit (30) and housing for retaining the lighting unit. The lighting unit has light emitting diodes (31), which are arranged on a printed circuit board (32). The light emitting diodes are formed as surface mount light emitting diode without outstanding lens part.