Monolithic LED Lighting Module for Indoor Farming
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Solution Overview
Problem
Current LED grow lights in indoor farming suffer from low photosynthetic photon efficacy due to light reflection and absorption by surfaces, as well as inefficiencies in white LEDs with embedded phosphors, leading to high energy consumption and operating costs.
Innovation Solution
A lighting module with a monolithic or multipart efficiency-enhancing optical element (EEOE) featuring a spectrum conversion layer, an optically transparent middle body with embedded LEDs, and a reflective back portion, made of polymeric materials like silicone, with a photoluminescent phosphor and titanium dioxide, designed for total internal reflection and radiation redirection to maximize light output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional LED grow lights are used, then the lighting system can provide illumination for plants, but the photosynthetic photon efficacy is low due to light reflection and absorption by surfaces
Solution Approach 1:
The patent extracts and removes the problematic reflective surfaces (PCB, heat sink, mounting structures) from the optical path by embedding the LED in a transparent encapsulant that fills the space around the LED. This eliminates the multiple reflections and absorptions that occur when light interacts with metallic and circuit board surfaces, directly improving photosynthetic photon efficacy.
Solution Approach 2:
The patent introduces a transparent encapsulant as an intermediary medium between the LED and the surrounding environment. This encapsulant has optimized optical properties (refractive index, transparency) that facilitate light extraction while preventing harmful reflections and absorptions, serving as a mediator that improves overall system efficiency.
2Illumination intensity
If white LEDs with embedded phosphor are used, then the lighting system can produce broad spectrum light, but the phosphor heats up and efficiency decreases
Solution Approach 1:
The patent extracts the phosphor from its traditional location directly on the LED die and relocates it to the transparent encapsulant surrounding the LED. This spatial separation removes the phosphor from the high-temperature zone near the LED junction, preventing thermal degradation while maintaining the phosphor's light-conversion function.
Solution Approach 2:
The transparent encapsulant serves as an intermediary that carries the phosphor away from the heat source. The encapsulant material is selected to have good thermal properties that prevent heat transfer to the phosphor, while still allowing efficient optical coupling between the LED and phosphor for broad spectrum light generation.
3Temperature
If remote phosphor configuration is used, then the phosphor is not close to the LED die, but significant part of the light emitted by the phosphor is directed back into the lighting device and reflected by surfaces
Solution Approach 1:
The patent applies local quality optimization by making the entire encapsulant transparent and optically active, rather than having localized reflective surfaces. The encapsulant is designed with specific refractive index and transparency properties in the regions where light travels, ensuring that light directed backward is transmitted through the transparent material rather than reflected, thereby reducing energy loss.
4Ease of manufacture
If conventional LED lighting structures are used, then the LED can be mounted on PCB and heat sink, but light is reflected by PCB and heat sink surfaces reducing useful light output
Solution Approach 1:
The patent merges the LED mounting structure, thermal management system, and optical enclosure into a single integrated transparent encapsulant. The encapsulant is formed directly over the LED, PCB, and heat sink, creating a unified structure that provides mechanical support, thermal conduction, and optimal optical properties simultaneously, eliminating the need for separate reflective surfaces.
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 significantly increases the photosynthetic photon efficacy of LED grow lights, reducing energy consumption and heat generation, thereby lowering operating costs and enhancing light delivery to plants.
Implementation Method 1
a front portion comprising a spectrum conversion layer
Implementation Method 2
said side surface is configured for: (a) reflecting said radiation emitted by said at least one light source toward said front portion by total internal reflection (TIR)
Implementation Method 3
a back portion configured to reflect said radiation emitted by said spectrum conversion layer to said cultivated crops
Data Source
AI summary
A lighting module for illuminating cultivated crops in indoor farming comprises at least one monolithic efficiency enhancing optical element (EEOE) further comprising: (a) a front portion comprising a spectrum conversion layer; (b) an optically transparent middle body portion having at least one light source embedded there within and configured to emit spectrally controllable radiation; and (c) a back portion configured to reflect the radiation emitted by the spectrum conversion layer to the cultivated crops. The back portion has a central area being adjacent to the optically transparent middle body portion configured for reflecting radiation propagating within the optically transparent middle body portion and a peripheral area configured for reflecting radiation emerged from the optically transparent middle body portion via the side surface.