Reconfigurable Multi-LED Light Source with Switching Substrate
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Solution Overview
Problem
The high initial and replacement costs of LED light sources due to complex configurations and the reduced efficiency and lifetime caused by increased current and temperature, as well as the increased probability of failure from multiple LEDs and connections, necessitate a solution for efficient and reliable light emission.
Innovation Solution
A light source with a switching substrate that allows for various configurations of LEDs, enabling flexible bias potentials and reconfiguration to maintain light output even with defective LEDs, using a two-dimensional array of LEDs that can be subdivided into identical multi-LED sources, with switches implemented as active or passive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a large number of LEDs are used to provide sufficient light output, then the light output and efficiency are improved, but the packaging costs and probability of failure increase
Solution Approach 1:
The LED array is segmented into multiple independently controllable groups or strings. Each group can be independently switched on or off, allowing the system to continue operating with reduced light output rather than complete failure when one group fails. This segmentation reduces the probability of total system failure while maintaining sufficient illumination.
Solution Approach 2:
The system dynamically reconfigures the LED connections between series and parallel arrangements based on operational conditions. When LEDs fail, the control circuit dynamically redistributes current to remaining functional LEDs, adjusting the configuration to maintain operation. This dynamic adaptation improves reliability by allowing the system to continue functioning despite individual LED failures.
2Illumination intensity
If a large number of LEDs are used to provide sufficient light output, then the light output is improved, but the packaging costs increase
Solution Approach 1:
A single LED array design serves multiple functions: it can be configured in different series/parallel arrangements to provide various light output levels, color temperatures, and operational modes. This universal design eliminates the need to manufacture separate packaging for different light output requirements, significantly reducing packaging costs while maintaining high light output capability.
Solution Approach 2:
The LED array uses dynamic switching between different circuit configurations (series and parallel) to achieve various light output levels without requiring physical reconfiguration or different packaging. This dynamic electrical reconfiguration allows one packaging design to serve multiple performance requirements, reducing manufacturing and packaging costs.
3Illumination intensity
If the current through LEDs is increased to improve light output, then the light output increases, but the efficiency and lifetime decrease
Solution Approach 1:
The total current is segmented and distributed across multiple LED groups rather than concentrating high current through a single LED or small number of LEDs. By dividing the LED array into parallel strings, each string carries lower current, reducing heat generation and extending LED lifetime while maintaining total light output through the combined contribution of multiple groups.
Solution Approach 2:
The system periodically switches between different LED groups, activating subsets of LEDs in sequence rather than continuously operating all LEDs at high current. This periodic operation allows individual LED groups to rest and cool down, extending their operational lifetime while maintaining average light output through sequential activation of different groups.
4Illumination intensity
If the current through LEDs is increased to improve light output, then the light output increases, but the efficiency decreases
Solution Approach 1:
The LED array is segmented into multiple parallel-connected groups, allowing the total current to be divided among them. This segmentation enables operation at lower current per group, reducing resistive power losses (I²R heating) and improving electrical-to-optical conversion efficiency while maintaining sufficient total light output through the combined emission of multiple groups.
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 packaging and inventory costs, extends the lifetime of the light source by allowing reconfiguration to compensate for failed LEDs, and improves electrical conversion efficiency by optimizing current distribution across LEDs, thereby reducing energy dissipation as heat.
Implementation Method 1
Light-emitting diodes (LEDs) are an important class of solid-state devices that convert electric energy to light
Data Source
AI summary
A light having a plurality of LEDs and a switching substrate is disclosed. The switching substrate is coupled to LEDs and includes a plurality of switches that provide a plurality of configurations for the LEDs. Each configuration is characterized by a two-dimensional array of LEDs having a minimum bias potential and a maximum bias potential, the LED array generating light when a bias potential is provided between the power terminals that is greater than the minimum bias potential, at least two configurations being operable to provide light at bias potential within this range. The switching substrate is sub-dividable into a plurality of identical multi-LED light sources by dividing the switching substrate along predetermined lines. The array of LEDs can be organized as a nested array of LEDs. The switches can be implemented as passive switches that are set by removing portions of conductors or bridging gaps in conductors.