Hexagonal LED Chipset for Uniform Light Mixing
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Solution Overview
Problem
Conventional high power illumination devices using metal halide discharge lamps have low lifespan and poor color saturation, while LED systems face light loss due to overlapping spectral ranges and non-uniform light distribution.
Innovation Solution
An LED unit module with a substrate and chipset featuring at least five closely arranged LED chips of various colors, including red, blue, green, amber, cyan, deep blue, and white/yellow, arranged in a hexagonal pattern to minimize light loss and ensure uniform light mixing, combined with a collimating unit and fly-eye lens pair for optimal light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple LED chips of different colors are arrayed to generate high brightness output light, then brightness is improved, but light loss due to filtering in overlapping spectral regions occurs
Solution Approach 1:
The patent merges multiple LED chips of different colors (red, green, blue, white) into a single integrated chipset arranged in a hexagonal pattern, allowing their light outputs to combine directly without intermediate filtering. This eliminates the light loss associated with dichroic filters while maintaining high brightness through the combined emission of multiple wavelength LEDs.
Solution Approach 2:
The hexagonal LED chipset design serves multiple functions simultaneously: it generates high brightness through multi-color LED combination, achieves uniform light distribution through its geometric symmetry, and eliminates spectral filtering losses by directly combining wavelengths. This multi-functional approach resolves the contradiction between brightness and light loss.
2Loss of energy
If LED chips of different colors are separated by distance to avoid spectral overlap, then light loss is reduced, but spatial distribution uniformity deteriorates
Solution Approach 1:
The patent employs a hexagonal arrangement of LED chips that combines symmetry with optimized spacing. The hexagonal geometry provides rotational symmetry for uniform light distribution while allowing adjacent chips to be positioned close together without causing spectral overlap issues, thus maintaining both low light loss and high uniformity.
Solution Approach 2:
The patent transitions from a linear or grid-based arrangement to a two-dimensional hexagonal packing arrangement. This dimensional change allows LED chips to be positioned in optimal locations that minimize both spectral overlap and spatial non-uniformity, achieving uniform light distribution across the entire emitting surface.
3Illumination intensity
If dichroic filters are used for wavelength-based light combination, then color saturation is improved, but light loss in overlapping spectral regions increases
Solution Approach 1:
The patent extracts and removes the dichroic filters from the light path, replacing them with a direct multi-color LED array. This elimination of the filtering component prevents light loss in overlapping spectral regions while maintaining color saturation through the inherent spectral characteristics of the LED chips themselves.
Solution Approach 2:
The patent converts the potential harm of spectral overlap (which causes light loss with filters) into a benefit by using multiple LEDs with overlapping spectra to directly generate a comprehensive color spectrum. The overlapping regions, rather than causing loss, contribute to enhanced color rendering and saturation through constructive combination.
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 achieves uniform light mixing and reduces etendue, enhancing the brightness and color rendering index of the light source system by ensuring spatial overlap and similar angular distributions of color lights, leading to improved light uniformity and efficiency.
Implementation Method 1
an LED chipset disposed on the substrate, wherein the LED chipset includes at least five LED chips that are arranged close to each other
Implementation Method 2
combined with a collimating unit and fly-eye lens pair for optimal light distribution
Data Source
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AI summary
An LED unit module (11), a light-emitting device (1), and a light source system. The LED unit module (11) comprises a substrate (13) and an LED chipset (14) arranged on the substrate (13). The LED chipset (14) comprises at least five LED chips, where the LED chips are in a tight arrangement with each other, and the contour of a light-emitting side of the LED chipset is close to a regular hexagon. The LED chipset (14) comprises LED chips of at least four colors, where the four colors are red, blue, green, and amber. The LED unit module (11) allows for prevention of increased etendue and for uniform mixing of lights.