Cost Reduction Strategies for LED Components

Lighting apparatus with a smart circuit that enhances lighting quality while reducing costs and damage from static electricity. The circuit includes a unique grounding structure and insulation around the LED chips. This protects against static discharge while providing flexible grounding connections to different parts of the circuit. The apparatus also has a wireless control circuit, a metal cover, and a metal housing for durability and easy installation.

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A large-area, low-cost OLED lighting module with high yield for general lighting applications. The module includes multiple OLED panels mounted on a flexible printed circuit sheet. The active area of each panel is optimized to maximize manufacturing yield. The panels can emit different colors. The module can include features like diffuser layers, sensors, and thin-film encapsulation for flexibility.

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High-yield, low-cost large-area flexible OLED lighting module that enables OLED light panels to be assembled into a large-area luminaire with high yield, low cost, high efficiency, and long lifetime. The module uses an optimized active area size to avoid particle defects. The OLED panels are bonded to a flexible printed circuit sheet, reducing non-emissive area compared to traditional OLED bonding methods.

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A technique for manufacturing efficient and cost-effective LED-based illumination devices. The method involves using arrays of separate optical elements and light-emitting elements that are assembled to create the illumination apparatus. The optical element array has electrodes to connect to the light-emitting elements.

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A highly efficient, low-cost LED-based illumination apparatus in which an array of optical elements is aligned with an array of tiny light-emitting diodes (LEDs) to improve the directionality and light extraction of the LED emission. The optical elements can be catadioptric, reflective, or refractive elements arranged in an array. The LEDs are formed on a separate substrate. When assembled, the optical elements focus and direct the LED light. The optical element array includes electrodes to connect to the LED array for powering the LEDs. The LED and optical element arrays can be manufactured separately and then aligned and combined. This allows for optimizing the LED and optical element designs independently.

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A lighting fixture with individually adjustable LEDs to provide illumination to a plurality of lighting areas. The fixture uses a plurality of mounting blocks with different pitches and heights to angle and position the LEDs in different directions. This allows the LEDs to be aimed independently to focus light in desired areas without using expensive lenses.

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Designing an LED lighting fixture that allows the use of standardized, low-cost components like LED strips and drivers to create a complete lighting product. The fixture uses a physical form that shapes the LED strip into a desired emission pattern when attached. It also includes constraint mechanisms to hold the strip in place. This allows using off-the-shelf LED strips rather than custom electronics. A positioning form for the driver is also provided. The physical forms can adapt strips and drivers to fit inside existing fixtures.

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A light source module with improved heat dissipation and fabrication efficiency without resorting to expensive materials. The module has a heat sink with an insulating layer to protect against electrical shock. An electrically conductive layer is embedded in the insulation to provide current to the light source. The conductive layer also has a heat dissipation portion to extract heat.

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A lighting module for vehicle headlights and other lighting applications that can simplify production and reduce costs compared to traditional connectors. The module has an electrical connector for connecting to vehicle wiring that is mounted directly to a heat sink using an electrical interconnection device such as a printed circuit board. This eliminates the need for a two-part connector with the second part joining after the heat sink mounting. The module design also includes a cavity on the heat sink to prevent electrical contact between the connector contacts and the sink.

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A modular multi-panel display system that uses interconnected LED display panels without cabinets to create large outdoor displays. The panels are mounted in a mechanical support structure. The display panels are hermetically sealed without cabinets and cooled passively. The panels interlock and share components like circuit boards and heatsinks to reduce cost and weight compared to having separate main and slave panels. The panels use potting compounds over the LEDs for environmental protection. The overall display mounts to a structure and has no cabinets or HVAC.

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Light engine for an LED light source that is lower cost, modular, and allows AC power input without complex circuitry. It achieves this by using multiple insulated substrates for the LEDs, driver circuitry, and protection, all bonded together. The LED elements are mounted on a substrate, with circuit substrates contacting it to apply voltage, and protection substrates surrounding all of it. This provides insulation between components and prevents shorts. The bonded substrates form a modular light engine that can be easily manufactured and scaled.

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Modular multi-panel LED display system that is low cost, lightweight, weatherproof, and doesn't require cabinets or active cooling. The display panels are designed to be interconnected without cabinets, using interlocking points, and hermetically sealed to protect the electronics from the environment. Heat sinks provide passive cooling. The panels have recessed printed circuit boards with LEDs, driver circuits, and potting compound over the LEDs.

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Modular multi-panel display system for billboards and outdoor signage that allows flexible sizing and easy replacement of panels. The display uses individual LED panels that can be joined together to form a larger display. The panels have interlocking attachment points to connect them. The panels are hermetically sealed without cabinets and cooled passively. Each panel has a heat sink that contacts the back of the casing and the printed circuit board to dissipate heat. This avoids the need for air conditioning. The display panels can be made with a main panel and smaller slave panels to reduce cost and weight. The modular panel design enables easy replacement of individual panels if they fail or need to be upgraded.

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Low-cost light emitting device with improved insulation between the LED elements. The device has linear wiring patterns on an insulating substrate with LED chips mounted between them. The LED chips are sealed together with a single sealing member. The linear arrangement of the LEDs allows for simple and cost-effective manufacturing. The linear wiring patterns provide electrical insulation between the LEDs.

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Modular driver module for light fixtures with LED luminaires that allows existing fixtures to be retrofitted with LEDs. The module generates the drive signals necessary to drive the LEDs, eliminating the need for LED luminaires to have their own driver electronics. The module can be located in a junction box or escutcheon plate of the fixture, and the existing sockets and wiring used to carry the drive signals to the LED bulbs. This avoids the need for specialized LED bulbs with built-in drivers, allowing standard bulb sockets to be used.

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