LED Array Zoom Spotlight Uniformity
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Solution Overview
Problem
Prior art zoom spotlights using incandescent or HID bulbs face issues with short lifetime, high heat generation, and high electrical power requirements, while LED-based spotlights struggle to achieve uniform light output due to spatial separation of LEDs, leading to complex and costly optics.
Innovation Solution
A densely-packed LED array with multiple wavelengths, supported by a substrate, emits light that is directed through optical elements such as a diffuser, aperture, and adjustable lenses to form a uniform spot beam with adjustable size and color, mimicking a point source for simplified optics and dynamic color mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If incandescent or HID bulbs are used as light sources, then high light output is achieved, but lifetime is short and heat generation is high
Solution Approach 1:
The patent changes the fundamental light source technology from thermal radiation (incandescent/HID) to electroluminescence (LED), representing a parameter change in the physical mechanism of light generation. This enables long lifetime while maintaining high light output through the use of multiple high-power LED chips arranged in an array configuration.
2Illumination intensity
If multiple individually-packaged LEDs are grouped to increase light output, then sufficient brightness is achieved, but optical complexity increases
Solution Approach 1:
The patent merges multiple high-power LED chips into a single integrated array structure mounted on a common substrate. This combining approach allows the LED array to function as a unified light source with sufficient total light output, while the regular spacing and common mounting plane simplify the optical design compared to grouping individually-packaged LEDs.
Solution Approach 2:
The patent transitions from one-dimensional linear LED arrangements to two-dimensional array configurations. This dimensional change enables sufficient light output through increased chip count while maintaining regular spacing patterns that simplify optical element design and positioning.
3Adaptability or versatility
If external filters are used to change color or color temperature, then color variation is achieved, but system cost and complexity increase
Solution Approach 1:
The patent performs preliminary action by incorporating multiple wavelength LED chips (red, green, blue, amber) directly into the light source array before light generation. This pre-integration of multiple wavelengths eliminates the need for external filters, as the desired colors and color temperatures are achieved through electronic control of the LED chip combinations.
Solution Approach 2:
The patent makes the light source universal by integrating multiple wavelength capabilities into a single LED array system. The same array can produce various colors and color temperatures by adjusting the activation and intensity of different LED chip types, eliminating the need for separate light sources or external filtering components.
4Illumination intensity
If bulb-based zoom spotlights are used, then uniform spot beam is achieved, but energy efficiency is low
Solution Approach 1:
The patent changes the light source from inefficient thermal radiation to efficient electroluminescence, representing a fundamental parameter change in energy conversion mechanism. The LED array achieves comparable beam uniformity to bulb-based systems while consuming significantly less electrical power and generating less heat.
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 long-lasting, energy-efficient zoom spotlight with uniform light intensity and adjustable color temperature, reducing the complexity and cost of optical elements while maintaining high light output, comparable to incandescent bulbs.
Implementation Method 1
at least one array of multiple LED chips without individual packaging supported by the substrate, wherein the LED chips emit light within the same or different wavelength ranges
Implementation Method 2
An optical device collects and directs light emitted by the LED chips of the at least one array along the axis
Implementation Method 3
The optical elements of a typical prior art zoom spot light may include reflectors, light scramblers or randomizers, apertures, and one or more lenses
Data Source
AI summary
A LED array spot illuminator for providing light along an optical axis comprises a substrate and at least one array of multiple LED chips without individual packaging supported by the substrate, wherein the LED chips emit light within the same or different wavelength ranges and are distributed laterally with respect to the axis over a light-emitting area. The LED chips have light emitting surfaces for emitting light in directions transverse to the area. An optical device collects and directs light emitted by the LED chips of the at least one array along the axis. An aperture passes the light emitted by the LED chips of the at least one array along the axis, wherein light collected by the optical device and passed by the aperture forms a beam of light illuminating a spot. Electric current is supplied to the multiple LED chips, causing them to emit light. Light emitted by the multiple LED chips that passed through the optical device and the aperture form a beam of light illuminating a spot. A distance between the multiple LED chips and one or more elements of the optical device is controlled to select a size of the spot.