Integrated LED Driver PCB for Exit Sign Retrofit
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Solution Overview
Problem
Existing LED luminaire systems require separate drivers, adding weight, cost, and the need for external wiring, which complicates their energy efficiency and reliability.
Innovation Solution
A single-board LED luminaire design with an integrated CL-1581 LED controller IC Chip and minimal external components, eliminating the need for a separate driver and heat sink, and using optimization techniques to allocate LEDs for efficient power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate LED driver is used, then the LED luminaire can be driven properly, but the weight and device complexity increase
Solution Approach 1:
The patent combines the LED driver circuit and LED array into a single integrated module. The driver IC is mounted directly on the same PCB as the LED arrays, eliminating the need for separate driver components and external wiring. This integration reduces overall weight while maintaining proper LED driving capability through optimized power distribution circuits.
2Reliability
If a separate LED driver is used, then the LED luminaire can be driven properly, but the device complexity and external wiring requirements increase
Solution Approach 1:
The driver circuit and LED arrays are merged into a single integrated module with all necessary power distribution traces fabricated directly on the PCB. This eliminates external wiring connections between separate driver and LED components, reducing installation complexity and potential connection failure points.
3Power
If traditional LED drivers are used, then proper power control is achieved, but heat dissipation requires additional heat sinks
Solution Approach 1:
The patent extracts the heat-generating driver circuitry from traditional separate driver designs and integrates it into a compact PCB layout with optimized thermal pathways. The driver IC is positioned to utilize the PCB as a heat sink, with thermal vias and copper traces designed to conduct heat away from the driver components to the PCB edges and mounting surfaces, eliminating the need for separate heat sink components.
4Ease of manufacture
If LEDs are arranged without optimization, then manufacturing is simpler, but energy efficiency and color temperature control deteriorate
Solution Approach 1:
The patent implements local quality optimization by dividing the LED array into multiple segments with different LED types (warm white, cool white, color LEDs) positioned in specific patterns. The driver circuit provides independent control channels to different LED groups, allowing localized adjustment of color temperature and intensity to optimize energy efficiency for different viewing conditions while maintaining a regular PCB layout for ease of manufacture.
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 results in a lightweight, reliable, and energy-efficient LED luminaire with reduced electromagnetic interference, no additional regulatory testing required, and high efficacy values, capable of continuous operation for 50,000 hours with minimal component replacement.
Implementation Method 1
The Light Emitting Diode emits electromagnetic waves in the visible portion of the electromagnetic spectrum
Implementation Method 2
The color of the light is determined by the band gap of the semiconductor. LED's using AlInGaP compound semiconductor alloys can emit in the yellow-red spectrum, while LED's using AlInGaN compound semiconductor alloys can emit in the UV-blue-green spectrum
Data Source
AI summary
A Light Emitting Diode (LED) Luminaire retrofit kit used with Exit Signs. This kit has an integral Driver On-Board (DOB) . The integrated Circuit Chip (IC Chip) on Printed circuit Board (PCB) eliminates the need for a separate LED Driver to drive the LEDs is on Board. The PCB includes a metal oxide varistor (MOV), and an array of Light Emitting Diodes (LEDs) arranged in an optimized configuration. An integral plastic Diffuser provides a uniform Light to the exit sign. All the components are laid out in a single low profile PC Board. The system provides maximum power output consuming very low input power. The system can operate at 120 or 277 Volts 60 Hz. The specially designed diffuser is positioned over LEDs for uniform illumination over desired area eliminating the Dot Matrix Pattern produced by LEDs. The luminaire can be made to varying lengths.