Staggered 2D LED Array for Uniform Large-Area Illumination

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Solution Overview

Problem

Switching the perceived color of large area lighting is challenging due to the need for combining LEDs or other light sources with thick, rigid, and expensive optics to evenly distribute light over large surfaces, making it prohibitively expensive for applications like walls or floors.

Innovation Solution

The use of 2D material-based LEDs, where multiple LEDs are combined into a single device with staggered configurations and individual power tuning to achieve homogeneous light emission without rigid optics, allowing for minimal controlling electronics and preventing light absorption by layering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If thick rigid optics are used to spread light evenly over large areas, then illumination uniformity is improved, but device complexity and cost increase

Engineering Contradiction:

Improveillumination uniformityVSAvoiddevice complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent divides the large area light emitting device into multiple smaller LED units arranged in a grid pattern. Each LED unit is independently controllable, allowing the system to achieve large area coverage without requiring complex optics. The segmentation enables modular design where simple LED components replace complex optical systems.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from using thick rigid optics (3D volume) to arranging multiple thin-film LED units in a planar grid configuration (2D arrangement). This dimensional change eliminates the need for bulky optical components while achieving the same light distribution function through spatial arrangement of multiple emitters.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Area of stationary object

If multiple LEDs are combined to cover large areas, then area coverage is improved, but controlling electronics complexity increases

Engineering Contradiction:

Improvearea coverageVSAvoidcontrolling electronics complexity

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The patent combines multiple LED units into a single integrated device structure where adjacent LEDs share common electrical connections. By merging the electrical pathways and control circuits, the system reduces the total number of independent control channels needed, thereby simplifying the controlling electronics while maintaining large area coverage.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent designs the LED array with universal control capabilities where a single control system can address and adjust multiple LED units. The controlling electronics are designed to universally manage the entire array through standardized interfaces, reducing complexity compared to requiring dedicated control circuits for each individual LED.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Loss of energy

If LEDs are arranged in staggered rows with different emission frequencies, then light absorption between layers is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improvelight absorption lossVSAvoidmanufacturing precision

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The patent assigns different emission frequencies (colors) to LEDs in different spatial locations within the array. Each local region has optimized LED characteristics matched to its position, creating local quality variations that prevent wavelength-dependent absorption issues while maintaining overall device performance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent varies the emission frequency parameter across different LED units in the array. By changing the operational parameter (wavelength) of adjacent LEDs, the system prevents resonant absorption between layers and improves overall light extraction efficiency, while the fabrication process remains compatible with standard multi-color LED manufacturing.

Inventive Principle:

Principle #35Parameter changes

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

Enables efficient, cost-effective coverage of large areas with tunable color perception and dimmable light output, reducing the need for extensive pixel control and minimizing the complexity of the light emitting device.

Implementation Method 1

a multi quantum well (MQW) semiconductor layer over the p-doped semiconductor layer

Methodology Applied

Scientific EffectElectroluminescence: Electroluminescence

Implementation Method 2

This prevents light emitted by deeper layer being absorbed by layers above

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Data Source

PatentUS11605756B2Light emitting device and method of making the same

Publication Date: 2023.03.14 PURDUE RES FOUND

AI summary

A light emitting device includes a first light emitting diode (LED). The first LED includes a first metallic layer. The first LED additionally includes a p-doped semiconductor layer over the first metallic layer. Additionally, the first LED includes a multi quantum well (MQW) semiconductor layer over the p-doped semiconductor layer. Moreover, the first LED includes an n-doped semiconductor layer over the MQW semiconductor layer. Next, the first LED includes a second metallic layer over the n-doped semiconductor layer. The light emitting device also includes a second LED over the first LED. Further, the light emitting device includes a third LED over the second LED.