White-Light LED Module Layout Without Spectrum-Separating Dams
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Solution Overview
Problem
Existing LED modules that emit white light require dams to separate different light spectra, which occupy valuable space and limit the light emission area, making it difficult to achieve a compact and cost-effective design with high efficiency.
Innovation Solution
The method involves arranging LED chips in a light field with a selective concentration of phosphor around each chip, eliminating the need for dams within the light field, allowing the entire area to be used for light emission or reducing the module size without performance loss. This is achieved by applying a phosphor-rich liquid potting compound and ensuring the phosphor settles only around the LED chips, with optional scattering particles for improved mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dams are used to separate different light spectra in LED modules, then light spectrum separation is improved, but light emission area is reduced
Solution Approach 1:
The invention extracts and removes the dams (partition walls) from the LED module structure. By eliminating these separating elements, the entire light field area becomes available for light emission, resolving the contradiction between spectrum separation and emission area. The spectrum separation function is achieved alternatively through selective phosphor arrangement around individual LED chips.
Solution Approach 2:
The invention applies local quality by selectively arranging phosphor around specific LED chips rather than using uniform separation structures. Each LED chip is surrounded by phosphor that converts its light output, creating localized spectrum control without requiring physical dams. This allows different spectral characteristics in different regions while maintaining full light emission area.
2Manufacturing precision
If dams are used to separate different light spectra, then light spectrum control is improved, but module size increases
Solution Approach 1:
The invention extracts and removes the dams (partition walls) from the LED module structure. By eliminating these separating elements, the entire light field area becomes available for light emission, resolving the contradiction between spectrum separation and emission area. The spectrum separation function is achieved alternatively through selective phosphor arrangement around individual LED chips.
Solution Approach 2:
The invention applies local quality by selectively arranging phosphor around specific LED chips rather than using uniform separation structures. Each LED chip is surrounded by phosphor that converts its light output, creating localized spectrum control without requiring physical dams. This allows different spectral characteristics in different regions while maintaining full light emission area.
3Volume of moving object
If the light field diameter is reduced for compact design, then module compactness is improved, but light emission area is insufficient
Solution Approach 1:
The invention merges the functions of light emission and spectrum conversion by integrating phosphor directly around each LED chip. This eliminates the need for separate dam structures and mixing chambers, allowing the entire light field to be used for emission. The compact design achieves sufficient light emission area by combining previously separate functional zones into a unified structure.
4Manufacturing precision
If mixing chamber is added for light homogenization, then light homogeneity is improved, but installation space increases
Solution Approach 1:
The invention merges the functions of light emission and spectrum conversion by integrating phosphor directly around each LED chip. This eliminates the need for separate dam structures and mixing chambers, allowing the entire light field to be used for emission. The compact design achieves sufficient light emission area by combining previously separate functional zones into a unified structure.
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 approach enables a more compact LED module with enhanced light emission efficiency, allowing for a larger light emission area or reduced module size while maintaining homogeneous white light output, and supports various color temperatures and shades of white light.
Implementation Method 1
a phosphor or a phosphor mixture is selectively arranged in an area around a respective LED chip
Implementation Method 2
different light spectra... blue light, red light and yellow light generated by a phosphor are emitted from the light points
Implementation Method 3
applying a phosphor-rich liquid potting compound and ensuring the phosphor settles only around the LED chips
Data Source
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AI summary
The invention relates to an LED module (10, 10', 10") for emitting mixed light, preferably white light, comprising: a module plate (11) having at least one ridge (12) which delimits a light field (13), wherein a plurality of LED chips (14, 14', 14", 14'") embedded in a casting compound (15) are arranged within the at least one light field (13); and wherein a fluorescent substance or a mixture of fluorescent substances (16, 17) is arranged selectively in the region around a respective LED chip (14, 14', 14", 14'"),. The invention further relates to a method for producing such an LED module (10, 10', 10") and to a lighting device having such an LED module (10, 10', 10").