Hybrid LED with Filter for Intensity and Color Consistency
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Solution Overview
Problem
Conventional LED light systems face challenges in maintaining intensity and color consistency within the target color regions as specified by the SAE J578 standard, particularly due to thermal degradation and the need for additional LEDs or heat sinks, which increase costs.
Innovation Solution
The integration of additional white LEDs with a skewed correlated color temperature and a filtering system that directs light through a primary optic to ensure a dominant portion of the light within the target color region, combined with a method for forming a printed circuit board with an integral heat sink using additional solder as a heat sink.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional narrow color-band LEDs are used to meet SAE J578 color specifications, then color consistency within target color regions is maintained, but light intensity is insufficient and requires additional LEDs or larger heat sinks
Solution Approach 1:
The patent combines a narrow color-band LED (for color accuracy) with a wide color-band LED of the same color (for intensity) into a single hybrid LED component. This merging allows the device to achieve both color consistency within SAE J578 target regions and sufficient light intensity without requiring multiple separate LEDs or larger heat sinks.
Solution Approach 2:
The hybrid LED uses composite material structures in its semiconductor layers, combining materials optimized for narrow bandwidth (color purity) with materials that provide higher luminous intensity. This composite approach at the material level enables simultaneous achievement of color accuracy and intensity within a single LED device.
2Illumination intensity
If additional LEDs are added to increase light intensity, then illumination intensity is improved, but thermal degradation increases and requires larger heat sinks
Solution Approach 1:
By merging the functions of color accuracy and intensity into a single hybrid LED, the patent eliminates the need for multiple separate LEDs that would each generate heat. The unified structure manages thermal load more efficiently, reducing thermal degradation while maintaining high intensity output.
Solution Approach 2:
The patent converts the potential harm of thermal degradation into a benefit by designing the hybrid LED with optimized internal heat distribution. The combined structure allows heat to be more evenly distributed and managed, transforming what would be a harmful concentration of thermal energy from multiple separate LEDs into a manageable thermal profile from a single integrated source.
3Illumination intensity
If white LEDs with skewed correlated color temperature are used to enhance intensity, then light intensity is improved, but color consistency may be compromised without filtering
Solution Approach 1:
The patent introduces a filter as an intermediary element between the wide color-band LED and the output. This filter selectively transmits wavelengths that enhance intensity while blocking wavelengths that would compromise color consistency, allowing the system to achieve both goals simultaneously.
Solution Approach 2:
The patent utilizes controlled color changes through the filter, which modifies the spectral output of the wide color-band LED. The filter adjusts the color temperature and wavelength distribution to maintain consistency with SAE J578 target regions while preserving the intensity enhancement provided by the wide color-band LED.
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 enhances the intensity and maintains color consistency within the target color regions, meeting the SAE J578 standards while reducing the need for additional LEDs and heat sinks, thereby lowering costs and improving thermal management.
Implementation Method 1
The filter is configured to suppress light outside of the target color region and a dominant portion of filtered light passing through the filter to the notional viewer at a midpoint of the viewing angle range is within the target color region
Implementation Method 2
The confining primary optic has a focus and a viewing angle range and is configured to direct light from the focus outwardly within the viewing angle range
Implementation Method 3
a second set of the solder portions is free of any electronic component leads. In some embodiments the second set of solder portions is disposed adjacent to a heat sink or heat dissipating structure
Implementation Method 4
a method for forming a printed circuit board with an integral heat sink using additional solder as a heat sink
Data Source
AI summary
The present disclosure describes light systems in which the intensity of base color LEDs configured to emit light within a target color region is increased using additional white LEDs and the emitted light is filtered so that a dominant portion of light passing through the filter at a particular viewing angle is within the target color region. The present disclosure also describes methods for forming a printed circuit board with an integral heat sink arrangement by depositing additional solder on solder pads that are not used to connect electronic components so that the additional solder acts as a heat sink.