Tunable Multi-LED Emitter Module for Consistent Color Temperature
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Solution Overview
Problem
Mass-producing LED-based lamps with consistent color temperature has proven challenging due to the sensitivity of the human eye to color-temperature variations, requiring either color binning with low yield or expensive mixing of different colors.
Innovation Solution
A tunable multi-LED emitter module with independently addressable groups of LEDs, where the color temperature is adjusted by varying the input current, and pre-tested information is stored in a memory device to provide the desired light color, allowing for stable color output without active feedback components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If color binning is used to ensure consistent color temperature, then color consistency is improved, but manufacturing yield deteriorates due to low yield in any particular bin
Solution Approach 1:
The invention divides the LED emitter into multiple groups (e.g., first group with cool white LEDs, second group with warm white LEDs) that can be independently controlled. This segmentation allows each group to be optimized for different color temperatures, enabling mass production with higher yield while maintaining overall color consistency through coordinated operation of multiple segments.
Solution Approach 2:
The invention changes the operating parameters (current levels) of different LED groups to achieve desired color temperature. By adjusting the relative current levels to each group, the system can tune the overall color output without requiring strict binning, thereby improving manufacturing yield while maintaining color consistency.
2Manufacturing precision
If multiple colors of light are mixed to produce desired temperature, then color temperature consistency is improved, but manufacturing cost deteriorates
Solution Approach 1:
The invention combines multiple LED groups with different color characteristics into a single integrated emitter module. By merging cool white and warm white LED groups in one package with shared control electronics, the system achieves color temperature consistency without the high costs associated with complex external mixing systems, reducing overall manufacturing cost.
Solution Approach 2:
The invention creates a universal emitter module that can produce multiple color temperatures by adjusting current levels to different LED groups. This multi-functional design eliminates the need for separate emitters for different color temperatures, simplifying manufacturing and reducing costs while maintaining consistent color output across different operating modes.
3Reliability
If active feedback components are used for tuning, then color stability is improved, but device complexity deteriorates
Solution Approach 1:
The invention performs color tuning during the manufacturing process by measuring the actual output of each LED group and programming the appropriate current levels into memory. This preliminary action ensures color stability without requiring active feedback components during operation, thereby maintaining reliability while minimizing device complexity.
Solution Approach 2:
The invention uses memory devices to store pre-determined current level settings that replicate the optimal color configuration. By copying the tuned settings into memory during manufacturing, the system maintains color stability without needing complex active feedback circuits, reducing overall system complexity.
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 enables the utilization of more LED dies, provides stable color temperature over time, and allows for versatile lighting applications by tuning the light output for different occasions, reducing manufacturing costs and increasing efficiency.
Implementation Method 1
two or more groups of light-emitting diodes (LEDs), each group having one or more LEDs
Data Source
AI summary
A method for making a light-emitting diode (LED) emitter module includes providing a substrate and providing two or more groups of LED dies disposed on the substrate. Each group has one or more LED dies, and each of the LED dies is coupled to an electrical contact and electrical paths are configured for feeding separate electrical currents to the groups of LED dies. The method also includes determining information associating a plurality output light colors with a corresponding plurality of combinations of electrical currents, each combination specifying a plurality of electrical current values, each electrical current value being associated with an LED die from one of the two or more groups of LED dies. The method also includes storing the information in the memory device, and providing a circuit for accessing the information in the memory device.