LED Module Pad Layout for Scalable Lumen Output and Color Mixing

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Solution Overview

Problem

Existing lighting devices face challenges in achieving scalable and uniform optical output with different lumen requirements due to the need for multiple PCB designs or the use of jumpers, which increase manufacturing costs and affect color uniformity.

Innovation Solution

A lighting device design featuring modules with LED chip connection pads arranged in a regular rectangular grid, allowing scalable LED configurations by omitting unwanted LEDs, and utilizing series-parallel interconnections to maintain electrical functionality and improve color mixing through optimized spacing and grouping of LEDs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple PCB designs are used to achieve different lumen outputs, then different LED configurations can be implemented, but manufacturing cost increases due to multiple PCB design and production

Engineering Contradiction:

ImproveLED configuration flexibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single PCB design is created that can serve multiple lumen output requirements (e.g., 10W, 15W, 20W) through configurable LED placement. The PCB includes all necessary connection pads and interconnection patterns to support different LED quantities and arrangements, eliminating the need for multiple specialized PCB designs and reducing manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The PCB design incorporates configurable elements that allow dynamic adjustment of LED configurations based on required lumen output. Connection pads and interconnection patterns are designed to accommodate variable LED placements, enabling the same PCB to adapt to different lighting requirements without requiring separate PCB designs for each power level.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If jumpers are used to reduce LED数量 on a single PCB design, then manufacturing cost is reduced, but color uniformity deteriorates due to disrupted LED arrangement

Engineering Contradiction:

Improvemanufacturing costVSAvoidcolor uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The PCB is divided into multiple groups of connection pads, with each group containing pads for LEDs of the same color point. This segmentation ensures that when LEDs are omitted or configured differently, the remaining LEDs within each group maintain their spatial relationships and color mixing characteristics, preserving color uniformity across different lumen output configurations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the PCB are designed with specific local characteristics - each group of connection pads is optimized for its particular color point combination. This local optimization ensures that regardless of which LEDs are activated, each local group maintains proper color mixing and uniformity, preventing the color non-uniformity issues that arise from random LED omission.

Inventive Principle:

Principle #3Local quality

3Illumination intensity

If LEDs are arranged in modules with optical units, then optical performance is improved, but color uniformity deteriorates when different color LEDs are used in the same module

Engineering Contradiction:

Improveoptical performanceVSAvoidcolor uniformity

Core Design Contradiction:

Illumination intensityVSManufacturing precision

Solution Approach 1:

Each module is segmented into groups of connection pads, with each group dedicated to a specific color point. This segmentation allows the optical unit to receive light from different color groups in a controlled manner, maintaining color uniformity while preserving the optical performance benefits of modular design with dedicated optical units.

Inventive Principle:

Principle #1Segmentation

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 scalable LED configurations without additional components, maintains electrical functionality, and enhances color uniformity and mixing, reducing manufacturing costs and improving optical performance.

Implementation Method 1

LED chips mounted on the connection pads

Methodology Applied

Scientific EffectLight emitting diode: Light Emitting Diode

Implementation Method 2

light emitting diodes arranged on the circuit board

Methodology Applied

Scientific EffectElectroluminescence: Electroluminescence

Data Source

PatentUS12510212B2Lighting device having groups of white and cyan LED chip

Publication Date: 2025.12.30 SIGNIFY HOLDING BV

AI summary

A lighting device includes multiple modules each having an array of LED chip connection pads, provided in groups, each group having a set of connection pads connected in parallel, with the groups being in series with each other. An optical unit is provided for shaping the light output from LED chips mounted on the pads. The groups are defined to minimize an overall spacing of the pads within the groups to mix light from the LEDs mounted on the connection pads.