LED Drive Circuit Eliminates Electrolytic Capacitors

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Current LED drive circuits with 3-5V forward voltage have complex designs due to restrictive devices like electrolytic capacitors and inductors, leading to low efficiency and power factor, high manufacturing costs, and inflexible application, especially when dealing with AC direct input solutions.

Innovation Solution

A drive circuit for an LED module comprising an LED array with parallel groups connected in series, a power supply module converting AC or DC power to 12V-75V, and a control module with gating switches and a control unit that synchronizes LED power with input voltage, eliminating the need for electrolytic capacitors and optimizing power factor and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrolytic capacitors and inductors are used in LED drive circuits, then power factor correction and voltage regulation are improved, but device complexity and manufacturing cost increase

Engineering Contradiction:
Improvepower factorVSAvoidcircuit complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates electrolytic capacitors and inductors from the traditional LED drive circuit, replacing them with a simplified switching circuit that uses only resistors, capacitors, and transistors. This removal of heavy restrictive devices directly reduces device complexity while maintaining power factor correction functionality through alternative circuit topology.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent substitutes the traditional electromagnetic-based power factor correction mechanism (using inductors and capacitors) with a semiconductor-based switching circuit. This replacement transitions from passive electromagnetic components to active semiconductor control, achieving the same power factor improvement with significantly reduced circuit complexity.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If electrolytic capacitors and inductors are used in LED drive circuits, then voltage regulation is improved, but manufacturing cost increases

Engineering Contradiction:
Improvevoltage regulationVSAvoidmanufacturing cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent removes expensive electrolytic capacitors and inductors from the circuit, replacing them with cheaper semiconductor components and passive elements. This extraction of costly components directly reduces manufacturing cost while the switching circuit topology maintains effective voltage regulation for the LED array.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs inexpensive semiconductor components and passive elements instead of expensive electromagnetic components. The simplified circuit uses readily available, low-cost parts that can be easily manufactured and replaced, significantly reducing overall manufacturing cost while maintaining functional performance.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Reliability

If complex circuits with multiple restrictive devices are used, then performance requirements are met, but development time and design complexity increase

Engineering Contradiction:
ImproveperformanceVSAvoiddevelopment time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The patent extracts and eliminates multiple restrictive devices from the traditional circuit design, creating a simplified topology that requires less development effort. By removing the need to design and tune complex electromagnetic circuits, the development time is significantly reduced while the core performance requirements are still met through the switching circuit approach.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent creates a universal circuit topology that can drive LED arrays of various configurations (series, parallel, or combinations) using the same basic switching circuit structure. This multi-functional design reduces development time by eliminating the need to design separate circuits for different LED configurations, as the same circuit can be adapted to various performance requirements.

Inventive Principle:
Principle #6Universality (Multi-functionality)

4Reliability

If AC direct input solution is implemented with traditional components, then power factor is improved, but device complexity and size increase

Engineering Contradiction:
Improvepower factorVSAvoidcircuit size
Core Design Contradiction:
ReliabilityVSVolume of moving object

Solution Approach 1:

The patent extracts and removes bulky electrolytic capacitors and inductors from the AC direct input circuit, replacing them with compact semiconductor switching components. This extraction dramatically reduces the physical size of the circuit while maintaining power factor correction capability through the switching topology, enabling compact LED lighting designs.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent substitutes traditional electromagnetic power factor correction components with semiconductor-based switching circuitry. This substitution transitions from bulky passive electromagnetic components to compact active semiconductor devices, achieving the same power factor improvement in a much smaller physical footprint suitable for modern compact LED fixtures.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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 solution achieves low power consumption, high power factor, and improved luminous efficiency by synchronizing LED current with input voltage, reducing manufacturing costs and design complexity, and enabling regular AC power supply without electrolytic capacitors.

Implementation Method 1

a power supply module, connected to an external AC or DC power supply and the LED array, and used for converting the external power supply into a 12V-75V forward voltage that drives each LED in the LED array

Methodology Applied
Scientific EffectPower conversion:

Implementation Method 2

a plurality of gating switches and a control unit, where the gating switches are disposed corresponding to the parallel groups and used for conducting or cutting off power supply loops of the parallel groups

Methodology Applied
Scientific EffectElectrical conduction and cutoff: Conduction (electrical)

Implementation Method 3

the control unit is used for controlling the gating switches to perform a conduction or cutoff operation according to a detected input voltage

Methodology Applied
Scientific EffectVoltage detection:

Data Source

PatentUS9445471B2Drive circuit for LED module
Publication Date: 2016.09.13 SHANGHAI YAMING LIGHTING
  • US9445471B2 patent drawing
  • US9445471B2 patent drawing
  • US9445471B2 patent drawing

AI summary

The present invention relates to a drive circuit of an light-emitting diode (LED) module, which includes: an LED array including a plurality of parallel groups connected in series; a power supply module for converting an external power supply into a 12V-75V forward voltage that drives each LED in the LED array; and a control module for controlling different gating switches to perform a conduction or cutoff operation according to a detected input voltage. The solution in accordance with the present invention can provide regular AC power for the LED array, without the need of providing an electrolytic capacitor. The present invention further overcomes design defects of a DC solution, optimizes the performance of a bulb, and reduces a manufacturing cost of the bulb. Compared with other lighting technologies, the AC solution reduces a total arrangement cost of the LED.