LED Chessboard Mounting for Color Consistency
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Solution Overview
Problem
Existing solid state lighting solutions using LED radiation sources are vulnerable to performance degradation due to the 'skipping' of sources during the mounting process, which can occur if one source is lost or faulty, leading to a loss of overall emission characteristics and color consistency.
Innovation Solution
A method involving a packaging unit with a specific sequence of LED sources from different bins arranged in a chessboard-like pattern on a substrate, allowing for flexible bin sequence combinations and minimizing the impact of losing a single source during mounting, by maintaining the sequential order and using a pick and place machine to position LEDs closely together with square separating spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If light radiation sources are placed closely together on a substrate to form a cluster, then production efficiency and compactness are improved, but the risk of performance degradation due to skipping during mounting increases
Solution Approach 1:
The patent divides the cluster into multiple groups, where each group contains light radiation sources from different bins arranged in a specific sequence. This segmentation ensures that if one source is skipped during mounting, the overall emission characteristics remain stable because each group contributes diversely to the total output.
Solution Approach 2:
The patent changes the arrangement parameters by organizing sources in sequences from multiple bins rather than using identical sources. By varying the bin origins and arranging them in specific patterns, the system maintains emission stability even when individual sources are missing.
2Manufacturing precision
If a combination of light radiation sources from different bins is used to compensate for manufacturing variations, then emission performance is improved, but logistics and storage complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-arranging light radiation sources from different bins in specific sequences on the substrate before mounting. This pre-arrangement ensures that the desired emission characteristics are achieved while simplifying logistics, as the pick and place machine only needs to follow the pre-determined sequence without complex real-time decisions.
3Manufacturing precision
If light radiation sources are arranged in successive sequences from different bins on a reel, then the desired emission characteristics are achieved, but the loss of a single source during mounting has a larger impact on overall performance
Solution Approach 1:
The patent segments the cluster into multiple groups with diverse bin compositions. This segmentation ensures that no single group is overly dependent on any specific bin, so the loss of one source does not significantly impact the overall emission characteristics.
Solution Approach 2:
The patent applies local quality by creating groups with different compositions from various bins at different locations in the cluster. Each group has tailored characteristics that contribute to the overall stability, ensuring that local variations do not propagate to affect the entire system's performance.
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 reduces the effect of losing a source on emission characteristics, maintaining color and flux consistency within a negligible deviation of 3% from expected values, ensuring minimal impact on the overall performance of the lighting device.
Implementation Method 1
solid state lighting sources (known as solid state lighting or SSL), using, for example, LED light radiation sources
Implementation Method 2
light radiation sources (of the LED type for example)
Data Source
AI summary
A method of placing on a mounting substrate (10) light radiation sources arranged in successive sequences (LED A, LED B, LED C, LED D) wherein each sequence includes light radiation sources (L) from different bins having respective light emission characteristics. The sequential order of recurrence of the light radiation sources of the various bins is repeated over the sequences. The light radiation sources (L) are placed on the mounting substrate (12) in at least two juxtaposed rows (18A, 18B), wherein each row (18A, 18B) includes light radiation sources arranged in a zigzag pattern to produce a chessboard-like array (18) of light radiation sources.