LED Module High-Density Arraying via 3D Wire Routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing LED modules require electrodes between each device, hindering high-density arraying due to the need for wire bonding, which complicates the emission of white and full-color light effectively.
Innovation Solution
An LED module design featuring a substrate with concentric frame members, where LEDs for white light are protected by phosphor resin within an inner frame, and colored LEDs are arrayed between the frames, with electrodes and metal wires strategically positioned to eliminate the need for additional electrodes between devices, allowing for high-density packing and independent control of light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrodes are disposed between each LED device for wire bonding, then reliable electrical connection is achieved, but device density is reduced due to space occupation by electrodes
Solution Approach 1:
The patent transitions from planar electrode arrangement to three-dimensional routing. Metal wires are led vertically through holes in the substrate to connect LEDs in different layers, allowing electrodes to be positioned only at perimeter regions rather than between each device. This dimensional change enables high-density LED arraying while maintaining reliable electrical connections.
Solution Approach 2:
The substrate serves multiple functions: it provides mechanical support, contains through-holes for wire routing, and acts as an insulating layer. The frame structure simultaneously defines mounting regions, provides structural support, and guides wire placement. This multi-functionality reduces the need for separate electrode structures between devices.
2Adaptability or versatility
If separate electrodes are provided for each LED device, then independent voltage application is enabled, but device complexity increases due to multiple electrode structures
Solution Approach 1:
The patent divides the LED array into multiple independent groups, each controllable by separate electrode pairs. White light LEDs form one group, while colored LEDs (red, green, blue) form additional groups. This segmentation allows independent voltage application to each group without requiring individual electrodes for every single LED, reducing overall structural complexity.
Solution Approach 2:
Metal wires act as intermediaries that route electrical connections from perimeter electrodes to internal LED devices. Instead of placing electrodes directly between each LED, the metal wires mediate the electrical connection by passing through substrate holes, simplifying the electrode structure while maintaining independent control capability.
3Quantity of substance
If metal wires straddle electrodes for connecting colored LEDs, then high-density arraying is achieved, but short-circuit risk increases between adjacent electrodes
Solution Approach 1:
The patent extracts the wire routing path from the plane of the electrodes by leading wires vertically through holes in the substrate. This separates the wire paths from the electrode structures, allowing metal wires to straddle electrodes without creating short-circuit risks. The harmful factor of short-circuiting is eliminated by spatial separation through the substrate thickness.
Solution Approach 2:
The metal wires are nested within holes of the substrate, passing through the insulating layer to connect LEDs. This nesting arrangement protects the wires from direct contact with electrodes while maintaining electrical connections, enabling high-density arraying without short-circuit risks.
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
Enables high-density arraying of LEDs while achieving efficient emission of white and full-color light without the need for intermediate electrodes, enhancing lighting performance and density.
Implementation Method 1
blue LEDs and a phosphor resin layer to emit yellow light of 3500K are disposed inside, and blue LEDs and a phosphor resin layer to emit white light of 6500K are disposed outside. The LED module mixes the yellow light and the white light
Data Source
AI summary
An object is to provide an LED module that eliminates the need for providing electrodes between each device and allows LEDs to be arrayed with high density. An LED module includes a substrate, a first frame member, a second frame member disposed outside the first frame member, a plurality of LEDs for producing white light disposed within the first frame member, a phosphor resin disposed within the first frame member, a plurality of LEDs for producing colored light disposed between the first frame member and the second frame member, and electrodes for applying a voltage to the plurality of LEDs for producing the white light, wherein a metal wire to connect the plurality of LEDs for producing the colored light to one another is disposed so as to straddle a part of each of the electrodes.