LED Module Radiation Uniformity Optimization
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Solution Overview
Problem
Existing LED modules face challenges in achieving uniform backlighting due to the inherent difficulty in constructing thin and uniform backlighting units, even with identical LEDs, and the variability of LEDs used in sequential production processes, leading to non-uniform radiation patterns.
Innovation Solution
An LED module with improved radiation uniformity is achieved by arranging light sources based on their color location and brightness, using a method that calculates optimal positions to ensure the radiation uniformity is less than the statistical mean of a random arrangement, employing a simulation method that models the brightness contribution as a parameterized function of location and other variables, and using numerical optimization to determine the best arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LEDs are arranged in a plane behind the display for backlighting, then the backlighting function is achieved, but the radiation uniformity is insufficient
Solution Approach 1:
The patent applies preliminary action by measuring and recording the color location and brightness of each LED during manufacturing, then using this pre-acquired data to calculate and determine the optimal arrangement positions before the actual module assembly. This preliminary characterization of individual LEDs enables the subsequent optimization of radiation uniformity without requiring complex optical components during operation.
2Manufacturing precision
If presorted LEDs with maximally uniform properties are used, then the color uniformity is improved, but the logistics complexity and measurement requirements increase exponentially
Solution Approach 1:
The patent applies parameter changes by utilizing the actual measured color location and brightness parameters of each individual LED to determine its optimal position in the module. Instead of requiring all LEDs to be identical through expensive presorting, the system adapts the arrangement based on the specific parameters of each LED, thereby achieving uniformity through configuration rather than through manufacturing precision alone.
3Productivity
If sequential production processes are used, then the manufacturing efficiency is maintained, but the radiation uniformity deteriorates due to LED variability
Solution Approach 1:
The patent applies copying by creating a digital model or data record of each LED's color location and brightness characteristics during production. This copied information is then used to determine the optimal arrangement, allowing sequential production processes to maintain efficiency while achieving uniform radiation patterns through data-driven positioning rather than requiring real-time adjustment during assembly.
Data Source
AI summary
An LED module includes a carrier and a number of light sources. Each light source is arranged on the carrier in such a way that the LED module comprises a radiation uniformity which is less than the statistical mean of a radiation uniformity distribution, wherein the radiation uniformity distribution is based on a plurality of LED modules with a random arrangement of the light sources.