LED Lighting Instrument Bin-Mixing Uniformity
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Solution Overview
Problem
Existing LED illumination apparatuses suffer from poor light output uniformity, leading to high fabrication costs due to the need to discard functional LED devices that do not meet binning requirements.
Innovation Solution
A cost-effective LED lighting instrument achieves improved light output uniformity by bin-mixing LED dies from different performance bins according to a predefined pattern, such as interleaving, on a substrate, and using a remote phosphor layer with a textured surface and diffuser particles to ensure consistent light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LED devices are sorted into bins based on light output characteristics, then light output uniformity is improved, but fabrication cost increases due to discarding functional devices that do not meet binning requirements
Solution Approach 1:
The patent changes the binning parameter from requiring all LEDs to fall within a narrow performance range to allowing LEDs from multiple bins (different performance ranges) to be mixed together. This parameter change enables the use of previously discarded functional devices while still achieving uniform light output through the mixing effect of different bin characteristics.
Solution Approach 2:
The patent applies local quality by strategically placing LEDs from different bins in specific locations on the substrate. By controlling the spatial distribution of LEDs with different light output characteristics, the invention achieves overall uniformity while utilizing devices that would otherwise be discarded from narrow binning ranges.
2Illumination intensity
If narrow binning ranges are used for LED devices, then light output uniformity is improved, but the quantity of usable LED devices decreases due to discarding out-of-spec devices
Solution Approach 1:
The patent fundamentally changes the binning approach by expanding the acceptable parameter range from narrow to wide. Instead of requiring all LEDs to fall within a tight specification range, the invention accepts LEDs across multiple bin ranges and uses their combined output to achieve uniformity, thereby dramatically increasing the quantity of usable devices.
Solution Approach 2:
The patent creates a composite LED array by combining devices from multiple bins with different light output characteristics. This composite approach allows the system to benefit from the diverse characteristics of different bin devices while achieving overall uniformity, effectively utilizing a larger quantity of functional devices.
3Ease of manufacture
If LEDs from different bins are mixed, then fabrication cost decreases by reducing waste, but light output uniformity becomes difficult to control
Solution Approach 1:
The patent applies local quality control by strategically positioning LEDs from different bins in specific spatial patterns on the substrate. By controlling the local distribution and density of LEDs from various bins, the invention maintains overall light output uniformity while utilizing a broader range of devices, thus reducing fabrication costs without sacrificing uniformity.
Solution Approach 2:
The patent transitions from one-dimensional binning (single performance range) to a multi-dimensional approach by considering spatial distribution patterns. By adding the spatial arrangement dimension to the binning strategy, the invention can mix LEDs from different bins while maintaining uniformity through controlled placement patterns.
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 bin-mixing approach reduces waste and fabrication costs while achieving uniform light output, allowing for the use of previously discarded LED devices, resulting in a more efficient and cost-effective lighting solution with improved color and brightness consistency.
Implementation Method 1
a phosphor layer located at a distance above the first LEDs and the second LEDs
Implementation Method 2
a light-reflective layer that is disposed on a surface of the phosphor layer
Implementation Method 3
using a remote phosphor layer with a textured surface and diffuser particles to ensure consistent light distribution
Data Source
AI summary
A lighting instrument includes: a substrate; a plurality of first light-emitting diodes (LEDs) disposed over the substrate, wherein the first LEDs each have a first value range for a light output characteristic; a plurality of second LEDs disposed over the substrate, wherein the second LEDs each have a second value range for the light output characteristic, the second value range being different from the first value range; a phosphor layer located at a distance above the first LEDs and the second LEDs; and a light-reflective layer that is disposed on a surface of the phosphor layer; wherein the first LEDs interleave with the second LEDs according to a predefined pattern.