LED Spectral Converter for Color Temperature and CRI Control
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Solution Overview
Problem
Manufacturing light sources with varying color temperatures and color rendering indexes (CRI) is challenging, as it requires complex binning and increases costs due to the need for multiple classifications, making it less cost-effective.
Innovation Solution
The use of spectral converters, composed of phosphorescent, fluorescent materials, or color pigments, within light-emitting diode (LED) assemblies to adjust the source spectral outputs, allowing for the production of lighting assemblies with similar form factors but dissimilar spectral outputs, thereby achieving desired color temperatures and CRI.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If spectral converters are integrated within light source packages to adjust spectral output, then diverse color temperatures and CRIs can be achieved, but manufacturing complexity increases due to integration requirements
Solution Approach 1:
The patent combines the spectral converter directly within the light source package, merging the LED chip, phosphor materials, and optical components into a single integrated unit. This integration allows diverse spectral outputs to be achieved without requiring separate adjustment mechanisms, thereby reducing overall system complexity while maintaining versatility.
Solution Approach 2:
The patent employs composite phosphor materials and spectral converting layers that combine multiple materials with different emission characteristics. By integrating these composite materials within the package, the system achieves broad spectral tuning capability without adding mechanical complexity, as the spectral conversion occurs passively through material properties rather than active control mechanisms.
2Manufacturing precision
If binning is required to supply light sources with different color temperatures and CRI, then manufacturing precision is maintained, but productivity decreases due to multiple classification categories
Solution Approach 1:
The patent achieves different color temperatures and CRI values by changing the composition and thickness of spectral converter layers rather than sorting LEDs into bins. By adjusting phosphor ratios, particle sizes, and layer configurations during manufacturing, a continuous range of spectral outputs can be produced from a single LED chip type, eliminating the need for post-manufacturing binning and classification.
Solution Approach 2:
The patent segments the spectral conversion function into multiple independent layers or zones within the package, each contributing to different portions of the spectrum. This allows precise control over color temperature and CRI through material composition rather than requiring precise sorting of individual LEDs, thereby maintaining manufacturing precision while improving production efficiency.
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
This approach enables the production of lighting assemblies with varied color temperatures and CRI using similar manufacturing equipment and methodologies, reducing costs and complexity while providing customizable lighting options.
Implementation Method 1
spectral converters, composed of phosphorescent, fluorescent materials, or color pigments
Implementation Method 2
spectral converters, composed of phosphorescent, fluorescent materials, or color pigments
Implementation Method 3
spectral converters, composed of phosphorescent, fluorescent materials, or color pigments
Data Source
AI summary
In one embodiment, a light-emitting device having a substrate, a casing, a plurality of light source dies, a plurality of spectral converters and a plurality of optical structures is disclosed. The spectral converters may be configured to spectrally adjust a portion of the light output of the light source die into a first and second converted spectral output that is substantially different from one another. In another embodiment, a system for illumination having a plurality of lighting assemblies has been disclosed. Each of the lighting assemblies comprises a light source die and a spectral converter. The spectral converter is configured to spectrally adjust the light output of the light source die so that the plurality of lighting assemblies are configured to emit substantially different spectral output. In yet another embodiment, a lighting apparatus having a primary spectral converter and a secondary spectral converter is disclosed.