Compact LED Module With Independent WRGB Segmentation
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Solution Overview
Problem
The low overall yield of WRGB devices during mass production due to defects in one of the four colors (W/R/G/B) hinders scalable manufacture and popularization in decorative lighting.
Innovation Solution
A compact LED module design featuring a printed circuit board with closely spaced white light and color light devices, where the white light devices include plastic housings, fluorescent glue, and metal fasteners, and the color light devices include red, green, and blue LEDs, with a distance fluctuation of no more than 0.5 mm between adjacent light exiting surfaces, allowing for independent packaging and improved yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If WRGB devices are adopted in mass production, then adjustable light of high brightness and wide-range chromaticity is achieved, but a fraction defective of any one of four colors W/R/G/B leads to relatively low overall yield
Solution Approach 1:
The WRGB device is divided into four independent monochromatic light devices (W, R, G, B), each packaged and tested separately. This segmentation allows each component to be produced and quality-checked independently, so that a defect in one color does not necessarily condemn the entire device, thereby improving overall yield while maintaining the capability to produce adjustable white light and full-color output.
2Volume of moving object
If devices are spaced closely within 1 mm, then space between devices is reduced and light mixing performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent achieves compact spacing by transitioning from planar arrangement to three-dimensional stacking, where monochromatic light devices are arranged vertically at different heights. This dimensional change allows devices to be positioned within 1 mm of each other while maintaining accessibility for manufacturing and assembly processes, thus reducing space requirements without proportionally increasing manufacturing complexity.
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 compact design enhances light mixing performance and increases the overall yield of LED modules, facilitating scalable manufacture and popularization by ensuring uniform color and brightness control.
Implementation Method 1
fluorescent glue disposed within the plastic housing
Data Source
AI summary
A LED module, comprising a printed circuit board, wherein the LED module further comprises a plurality of light emitting units provided onto the printed circuit board, wherein each light emitting unit comprises a plurality of white light devices sets and/or a plurality of color light devices sets spaced less than 1 mm between one another.