JP-7856268-B2 - LED module and vehicle headlight having such LED module

JP7856268B2JP 7856268 B2JP7856268 B2JP 7856268B2JP-7856268-B2

Inventors

デッカーズ，ミヒャエル

Assignees

ルミレッズリミテッドライアビリティカンパニー

Dates

Publication Date: 20260511
Application Date: 20220711
Priority Date: 20210709

Claims (20)

A light-emitting diode (LED) device having a first LED module, The first LED module is A substrate having a mounting surface, The first is a two-column composite two-dimensional array, A first two-dimensional array having a first plurality of LEDs in two rows on the mounting surface of the substrate, wherein all of the first plurality of LEDs have the same first orientation, and a second two-dimensional array adjacent to the first two-dimensional array, having a second plurality of LEDs in two rows on the mounting surface of the substrate, wherein all of the second plurality of LEDs have the same second orientation, A first two-row composite two-dimensional array having, A plurality of first electrical traces on the mounting surface, which start from opposite corners of the first two-row composite two-dimensional array and alternate between the two rows of each of the first two-dimensional array and the second two-dimensional array, thereby electrically coupling the plurality of first LEDs and the plurality of second LEDs in sequence to form a first LED string and a second LED string, wherein each of the first LED string and the second LED string has a start end and an end end, A second electrical trace on the mounting surface is electrically coupled between the end of the first LED string and the end of the second LED string, crossing the two rows of the two-row composite two-dimensional array, A plurality of third electrical traces located on the mounting surface and routing outside the first two-row composite two-dimensional array, wherein the first of the plurality of third electrical traces is electrically coupled to the starting end of the first LED string with respect to the row of the first two-row composite two-dimensional array including the starting end of the first LED string, the second of the plurality of third electrical traces is electrically coupled to the starting end of the second LED string with respect to the other row of the two-row composite two-dimensional array, the third of the plurality of third electrical traces is electrically coupled to the end of the first LED string with respect to the other row of the two-row composite two-dimensional array, and at least one fourth of the plurality of third electrical traces is electrically coupled to at least a portion of the electrodes of the LEDs in the other row, A device having
The device according to claim 1, wherein the plurality of third electrical traces route all the electrodes of the LEDs of the other row outside the two-row composite two-dimensional array.
A second LED module mounted on the substrate , wherein the orientation, relative arrangement, and electrical connection of the second LEDs of the second LED module are mirror images of the orientation, relative arrangement, and electrical connection of the first LEDs of the first LED module with respect to the outer line of the two-row composite two-dimensional array of the second LED module, and the line is one of a vertical line adjacent to the starting end of the second LED string and a horizontal line adjacent to the starting end of the first LED string. The device according to claim 1, further comprising the above.
A third LED module mounted on the substrate, wherein the orientation, relative arrangement, and electrical connection of the third LED of the third LED module are mirror images of the orientation, relative arrangement, and electrical connection of the second LED of the second LED module with respect to the other of the vertical and horizontal lines. The device according to claim 3, further comprising the above.
A switch on the mounting surface, each of which is electrically coupled in parallel to one of the LEDs via two of the third electrical traces, The device according to claim 1, further comprising the above.
The device according to claim 5, further comprising a controller located on the mounting surface and communicably coupled to the control port of the switch via a fourth electrical trace.
A connector located on the mounting surface, electrically coupled to the start and end ends of the first LED string and the second LED string by one of the third electrical traces, and electrically coupled to the controller by one or more fifth electrical traces, The device according to claim 6, further comprising the above.
The device according to claim 1, wherein the first LED string and the second LED string each have 3 to 30 LEDs.
The device according to claim 1, wherein adjacent LEDs in the two-row composite two-dimensional array are spaced less than 100 μm apart.
The device according to claim 1, wherein the substrate comprises one of a heat sink, an IMS, and a PCB made of AlN, having a metallization layer for forming the electrical traces on the mounting surface.
The device according to claim 1, wherein the LED is mounted on the substrate using WLP technology.
The device according to claim 1, further comprising an optical component for receiving light emitted from the LED during operation.
Vehicle headlights, Fixing device, LED module and The LED module has, A substrate having a mounting surface, It is a two-column composite two-dimensional array, A first two-dimensional array having a first plurality of LEDs in two rows on the mounting surface of the substrate, wherein all of the first plurality of LEDs have the same first orientation, and a second two-dimensional array adjacent to the first two-dimensional array, having a second plurality of LEDs in two rows on the mounting surface of the substrate, wherein all of the second plurality of LEDs have the same second orientation, A two-row composite two-dimensional array having, A plurality of first electrical traces on the mounting surface, which start from opposite corners of the two-row composite two-dimensional array and alternate between the two rows of each of the first two-dimensional array and the second two-dimensional array, thereby sequentially electrically coupling the plurality of first LEDs and the plurality of second LEDs to form a first LED string and a second LED string, wherein each of the first LED string and the second LED string has a start end and an end end, A second electrical trace on the mounting surface is electrically coupled between the end of the first LED string and the end of the second LED string, crossing the two rows of the two-row composite two-dimensional array, A plurality of third electrical traces located on the mounting surface and routing outside the two-row composite two-dimensional array, wherein a first of the plurality of third electrical traces is electrically coupled to the starting end of the first LED string with respect to the row of the two-row composite two-dimensional array including the starting end of the first LED string, a second of the plurality of third electrical traces is electrically coupled to the starting end of the second LED string with respect to the other row of the two-row composite two-dimensional array, a third of the plurality of third electrical traces is electrically coupled to the end of the first LED string with respect to the other row of the two-row composite two-dimensional array, and at least one fourth of the plurality of third electrical traces is electrically coupled to at least a portion of the electrodes of the LEDs in the other row, Vehicle headlights.
The vehicle headlight according to claim 13, wherein the plurality of third electrical traces route all the electrodes of the LEDs of the other row outside the two-row composite two-dimensional array.
A switch on the mounting surface, each of which is electrically coupled in parallel to one of the LEDs via two of the third electrical traces, The vehicle headlight according to claim 13, further comprising:
The vehicle headlight according to claim 15, further comprising a controller located on the mounting surface and communicably coupled to the control port of the switch via a fourth electrical trace.
A connector located on the mounting surface, electrically coupled to the start and end ends of the first LED string and the second LED string by one of the third electrical traces, and electrically coupled to the controller by one or more fifth electrical traces, The vehicle headlight according to claim 16, further comprising:
The vehicle headlight according to claim 13, wherein adjacent LEDs in the two-row composite two-dimensional array are spaced less than 100 μm apart.
The vehicle headlight according to claim 13, wherein the first LED string and the second LED string each have 3 to 30 LEDs.
A method for manufacturing an LED module, This involves forming a two-row composite two-dimensional array on the mounting surface of the substrate. A first two-dimensional array is formed on the mounting surface of the substrate, having two rows of first plurality of LEDs on the mounting surface, and all of the first plurality of LEDs have the same first orientation. Adjacent to the first two-dimensional array, a second two-dimensional array is formed having two rows of second plurality of LEDs on the mounting surface of the substrate, and all of the second plurality of LEDs have the same second orientation. The plurality of first electrical traces on the mounting surface are formed in such a way that they start from opposing corners of the two-row composite two-dimensional array and alternate between the two rows of the first two-dimensional array and the second two-dimensional array, so that the plurality of first electrical traces sequentially electrically connect the plurality of first LEDs and the plurality of second LEDs to form a first LED string and a second LED string, and each of the first LED string and the second LED string has a start end and an end end. The second electrical trace on the mounting surface is formed in such a position that it crosses the two rows of the two-row composite two-dimensional array and is electrically coupled between the end of the first LED string and the end of the second LED string. A plurality of third electrical traces on the mounting surface routing the outside of the two-row composite two-dimensional array are formed such that a first of the plurality of third electrical traces is electrically coupled to the starting end of the first LED string in relation to the row of the two-row composite two-dimensional array including the starting end of the first LED string; a second of the plurality of third electrical traces is electrically coupled to the starting end of the second LED string in relation to the other row of the two-row composite two-dimensional array; a third of the plurality of third electrical traces is electrically coupled to the end of the first LED string in relation to the other row of the two-row composite two-dimensional array; and at least one fourth of the plurality of third electrical traces is electrically coupled to at least a portion of the electrodes of the LEDs in the other row. By doing so, a two-row composite two-dimensional array is formed. A method of having.

Description

(Cross-reference of related applications) This application claims the benefits of U.S. Provisional Patent Application No. 63/220,154, filed on 9 July 2021, which are incorporated herein by reference. This application is related to U.S. Patent Application No. 16/681,144, filed on 12 November 2019, which are incorporated herein by reference. Light-emitting diodes (LEDs), encompassing all semiconductor light-emitting devices including, for example, diode lasers, and without distinguishing between LED dies and packaged LEDs, are increasingly replacing older light sources due to their superior technical characteristics, such as energy efficiency and lifespan. This can also apply to applications with demanding requirements in terms of brightness, luminous intensity, and/or beam shaping, such as vehicle headlighting. Of particular interest are LEDs arranged in a two-dimensional spatial array. The partial or complete single-addressing capability of LEDs within such an array can enable advanced applications in all lighting fields, such as general lighting, flash, and especially vehicle headlighting, such as advanced driving beams (ADBs). The composite array has two two-dimensional arrays on a substrate, each having two rows of LEDs. The LEDs in each array have the same orientation as all other LEDs in that array. Multiple first electrical traces sequentially connect the LEDs in the first and second strings by starting from opposing corners of the composite array and alternating between each row of the first and second arrays. Second electrical traces connect the ends of the first and second strings across the rows of the composite array. Multiple third electrical traces route outside the composite array, connecting to the start of the first string for the row of the composite array containing the start of the first string, to the start of the second string for the other row, to the end of the first LED string for the other row, and to the electrodes of the LEDs in the other row. A more detailed understanding can be gained from the following explanation, which is provided as an example along with the attached diagram. This is a schematic diagram of an example of an LED lighting device circuit. Figure 1 is a schematic diagram of the spatial arrangement of LEDs, showing an example of the electrical connection of the LEDs. This is a schematic diagram of an example of an LED module, partially compared with the LED lighting device shown in Figure 1. This is a schematic diagram of another example of an LED module. This is a schematic diagram of yet another example of an LED module. This is a diagram illustrating an example of a vehicle headlamp system. This is a diagram of another example of a vehicle headlamp system. This is a flowchart illustrating one example of a method for manufacturing LED modules. The following examples of several different light illumination systems and/or light-emitting diode ("LED") implementations are more fully illustrated with reference to the attached drawings. These examples are not mutually exclusive, and features from one example can be combined with features from one or more other examples to achieve further implementations. Therefore, it should be understood that the examples shown in the attached drawings are provided for illustrative purposes only and are not intended to limit this disclosure. Throughout, similar elements are referred to by similar numerals. To be understood, terms such as first, second, third, etc., may be used here to describe various elements, but these elements should not be limited by these terms. These terms may be used to distinguish one element from another. For example, without departing from the scope of the invention, the first element may be referred to as the second element, and the second element may be referred to as the first element. As used herein, the terms “and/or” may include any and all combinations of one or more items from the items enumerated in relation. It is understood that when an element such as a layer, region, or substrate is referred to as being “on top of” or “extending upward” another element, it may be directly on top of or extending directly onto the other element, or there may be an intervening element. In contrast, when an element is referred to as being “directly on top of” or “extending directly upward” another element, there may be no intervening element. It is also understood that when an element is referred to as being “connected” or “joined” to another element, it may be directly connected or joined to the other element, and/or connected or joined to the other element via one or more intervening elements. In contrast, when an element is referred to as being “directly connected” or “directly joined” to another element, there is no intervening element between that element and the other element. It is understood that these terms are intended to include elements in orientations other than those depicted in the diagram. Here, rel