Multilayer PCB LED Driver for Compact Black Body Lighting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing LED lighting systems with separate drivers for different LEDs are costly and complex, and they are not suitable for applications with tight spatial constraints due to separate device housings and electrical connections.
Innovation Solution
A compact, multilayered LED driver with integrated LEDs and wireless capabilities, featuring a multilayer PCB design that includes color temperature mixing and a microprocessor, allowing for independent control of LED channels to replicate black body curve light temperatures, while fitting into existing fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate drivers are used for different LEDs, then individual LED control is achieved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple LED drivers into a single integrated driver unit that controls multiple LED channels simultaneously. This single driver integrates the control functionality for different colored LEDs (white, amber, etc.) into one unified device, eliminating the need for separate driver units while maintaining individual channel control capability through integrated control circuitry and a single microprocessor.
2Reliability
If separate device housings are used for drivers and LED light sources, then electrical connections can be established, but spatial constraints are not met
Solution Approach 1:
The patent merges the driver unit and LED light source into a single integrated fixture housing. The driver circuitry, power supply, and LED arrays are all housed together in one compact unit, eliminating the need for separate housings and electrical cables while maintaining reliable electrical connections through internal PCB traces and solder joints.
Solution Approach 2:
The integrated fixture serves multiple functions within a single device: it contains the power supply circuitry, LED driver control, multiple colored LED arrays, and housing all in one unit. This multi-functional design replaces what would traditionally require separate devices for power supply, control, and light emission.
3Ease of manufacture
If a single layer PCB is used, then manufacturing is simpler, but component mounting area is insufficient
Solution Approach 1:
The patent transitions from a single-layer PCB to a multi-layer PCB design. This adds the vertical dimension to the component layout, allowing components to be mounted on multiple layers stacked vertically. The multi-layer structure provides significantly more mounting area for power electronic components, capacitors, inductors, and control circuitry while maintaining a compact footprint that fits within the integrated fixture housing.
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 provides a cost-effective, compact, and functional LED lighting system that can mimic black body radiator color temperatures, enabling efficient light intensity and color mixing within tight spatial constraints.
Implementation Method 1
A light emitting diode (LED) is an electronic device that converts electrical energy (commonly in the form of electrical current) into light
Implementation Method 2
The LED driver is configured to change the intensity of the light emitted and to adjust the color mixing of the LED channels to replicate light temperatures, which follow the black body curve
Implementation Method 3
The first board includes a metal core layer configured to be mounted to a fixture, the metal core layer being opposite from the plurality of LEDs
Data Source
AI summary
An integrated multi-layered lighting system includes a first board having a first component area and a first light area, a second board coupled to and offset from the first board, the second board having a first opening overlapping the first light area of the first board in a plan view, and a second component area overlapping the first component area of the first board in a plan view, a plurality of light emitting diodes (LEDs) coupled to the first board and positioned in the first light area corresponding to the first opening of the second board, and a light driver configured to drive the plurality of LEDs and including a plurality of first components coupled to the first board and positioned in the first component area and a plurality of second components coupled to the second board and positioned in the second component area.