LED Module Three-Part Color Matching
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Solution Overview
Problem
Current LED illumination devices face limitations in light output, color quality stability, and high costs due to temperature constraints, color point instability, and the need for precise color control, which affects their efficiency and effectiveness in producing consistent and desired color points.
Innovation Solution
A light emitting diode (LED) module is designed with a light mixing chamber incorporating two selectable wavelength converting components with different properties, allowing for precise control of the spectral power distribution to achieve a target color point within a predetermined tolerance, thereby enhancing color stability and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wavelength converting material is used to control color point, then color point precision is improved, but device complexity increases due to required color control electronics and sensors
Solution Approach 1:
The patent uses inexpensive wavelength converting materials (phosphors) with fixed characteristics instead of expensive, complex electronic color control systems. The phosphor materials are applied to reflective surfaces within the LED module housing, providing color control without requiring sensors or active electronics.
Solution Approach 2:
The patent replaces electronic color control mechanisms with an optical solution using wavelength converting materials. Instead of using electronics and sensors to dynamically control color, the invention uses passive optical components (phosphor-coated reflective surfaces) to achieve color point precision.
2Manufacturing precision
If only a small selection of LEDs meeting color and flux requirements is used, then color quality is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the approach from selecting LEDs with precise color characteristics to using wavelength converting materials that transform the LED spectrum. By applying phosphors with specific emission characteristics to reflective surfaces, the system achieves consistent color output from LEDs with broader spectral variations, thereby reducing selection constraints and manufacturing costs.
Solution Approach 2:
The patent introduces wavelength converting materials as an intermediary between the LED source and the final light output. These materials act as a mediator that transforms the LED spectrum into a consistent color output, eliminating the need to strictly select LEDs based on color specifications.
3Illumination intensity
If LED temperature is increased to improve light output, then illumination intensity is improved, but LED chip lifetime decreases
Solution Approach 1:
The patent uses wavelength converting materials as an intermediary that converts LED light to the desired color spectrum without requiring high LED operating temperatures. The phosphors on the reflective surfaces convert the LED output to achieve target color points, allowing lower temperature operation that extends LED lifetime while maintaining illumination intensity.
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 enables the production of LED modules that consistently produce light with a target color point within a small tolerance, improving color rendering and reducing the need for expensive color control electronics, while accommodating a wide range of LED spectral power distributions.
Implementation Method 1
A first selectable component has a first type of wavelength converting material with a first wavelength converting characteristic and a second selectable component has a second type of wavelength converting material with a different wavelength converting characteristic. The first and second wavelength converting characteristics alter the spectral power distribution of the light produced by the LED
Data Source
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AI summary
A light emitting diode module (100) is produced using at least one light emitting diode (LED) (114) and at least two selectable components that form or are part of a light mixing chamber (101) that surrounds the LEDs and includes an output port. A first selectable component (130) has a first type of wavelength converting material (132) with a first wavelength converting characteristic and a second selectable component (126) has a second type of wavelength converting material (128) with a different wavelength converting characteristic. The first and second wavelength converting characteristics alter the spectral power distribution of the light produced by the LED to produce light through the output port (122) that has a color point that is a predetermined tolerance (259) from a predetermined color point (257). Moreover, a set (500) of LED modules may be produced such that each LED module has the same color point within a predetermined tolerance. The LED module may be produced by pre-measuring the wavelength converting characteristics of the different components selecting components with wavelength converting characteristics that convert the spectral power distribution of the LED to a color point that is a predetermined tolerance from a predetermined color point.