LED Array Light Source with Asymmetric Submount
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Solution Overview
Problem
Existing LED lighting fixtures face challenges in achieving high illumination over large areas with specific light-distribution requirements, particularly in applications like roadway lighting, where minimizing complex reflectors and varying light source orientations is desirable.
Innovation Solution
An LED light source with a submount featuring an LED-populated area of aspect ratio greater than 1, an array of LEDs closely spaced to cover at least one-third to nearly the entire area, and a lens offset from the emitter axis to refract light towards a preferential direction, providing efficient and targeted illumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If traditional LED fixtures use multiple light sources with varying orientations and complex reflectors to achieve desired illumination patterns, then light distribution requirements are met, but device complexity increases
Solution Approach 1:
The invention divides the LED light source into multiple discrete LEDs arranged in a specific geometric pattern (e.g., triangular, rectangular, or other polyhedral configurations) on an aspect ratio greater than 1 substrate. This segmentation allows each LED to contribute to the overall illumination pattern, achieving complex light distribution through simple individual elements rather than requiring complex reflectors or varying orientations.
Solution Approach 2:
The invention employs an asymmetric substrate geometry with an aspect ratio greater than 1, which inherently directs light distribution in preferred directions. This asymmetric configuration eliminates the need for complex symmetric reflector systems or multiple light sources with varying orientations, as the asymmetric LED array itself generates the desired non-uniform illumination pattern for applications like roadway lighting.
2Area of stationary object
If LED arrays are densely packed to cover large areas, then illumination coverage is improved, but manufacturing precision requirements increase
Solution Approach 1:
The invention specifies that LEDs be positioned at vertices or along edges of geometric shapes (triangles, rectangles, or other polyhedra) rather than requiring uniform dense packing across the entire substrate. This local quality approach means LEDs are placed only where needed to define the geometric pattern, reducing the total number of LEDs required and consequently lowering manufacturing precision requirements while still achieving large area coverage through the aspect ratio greater than 1 configuration.
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 enables effective illumination patterns with reduced complexity and orientation variability, achieving desired light distribution in large areas such as roadways with improved efficiency and reduced light spillage off the intended area.
Implementation Method 1
The LED array defines an emitter axis, and in certain embodiments the lens has an outer surface and a centerline which is offset from the emitter axis toward the preferential direction. In some of these embodiments, the lens is shaped for refraction of LED-emitted light toward the preferential direction.
Data Source
AI summary
An LED light source for use in LED lighting fixtures, the LED light source comprising a submount including an LED-populated area which has an aspect ratio greater than 1, an array of LEDs on the LED-populated area, and a lens on the submount over the LED-populated area. Various embodiments facilitating preferential-side lighting, such as for roadway uses, are also disclosed.