Pixelated LED Module for Channel Letter Illumination
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Solution Overview
Problem
Channel letter signage using traditional LEDs faces inefficiencies in heat dispersion due to closed construction, leading to reduced LED life and intensity, as heat sinks are necessary to manage heat but are slow and costly.
Innovation Solution
The use of a plurality of smaller through-hole LEDs arranged in a pixel formation within a plastic casing, eliminating the need for heat sinks by reducing heat generation and energy consumption, with a larger beam angle for improved light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a single large LED is used in channel letter signage, then light intensity is achieved, but heat generation increases and LED life decreases
Solution Approach 1:
The patent divides a single large LED into multiple smaller LEDs arranged in a pixel formation. This segmentation allows the same light intensity to be achieved through multiple lower-power LEDs, reducing heat generation per LED and extending operational life while maintaining illumination requirements.
2Temperature
If heat sinks are added to LED modules, then heat dispersion is improved, but device complexity and cost increase
Solution Approach 1:
The patent removes the heat sink component entirely from the LED module by using smaller LEDs that generate less heat. This extraction of the heat sink eliminates the associated complexity and cost while the smaller LEDs inherently produce manageable heat levels that do not require additional heat dissipation structures.
3Use of energy by moving object
If smaller LEDs are used, then energy consumption and heat generation are reduced, but light intensity decreases
Solution Approach 1:
The patent combines multiple smaller LEDs into a pixel formation where their light output is aggregated to achieve the required illumination intensity. This merging allows the system to benefit from the lower energy consumption and heat generation of small LEDs while collectively producing sufficient light for channel letter signage applications.
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 solution reduces energy costs and construction costs by minimizing heat generation and the need for heat sinks, while maintaining or improving light intensity and longevity of the LEDs.
Implementation Method 1
LEDs have been used in commercial signage applications, particularly in channel letters in place of neon and other fluorescent lighting
Data Source
AI summary
The present invention is an LED module for channel letter illumination utilizing multiple through-hole LEDs in a pixel formation as a light source where one surface mounted LED or other forms of LEDs were previously used. The use of a number of small through-hole LEDs ideally requires that a beam angle between and including 15° and 180° in vertical and horizontal directions, respectively, be utilized. When multiple light sources are used on a module, the distance between light sources is to be between 20 mm and 1 cm. The use of several smaller LEDs reduces the current needed to generate light of appropriate intensity and, thus reduces energy cost and heat generation. The use of smaller LEDs also assists in excess heat dissipation.