Miniaturization Techniques for LED Lighting Components
15 patents in this list
Updated:
Modern LED lighting systems face increasing pressure to deliver higher luminous output from ever-smaller form factors. Current designs must fit within volumes under 5000 mm³ while maintaining light output above 150 lumens and managing thermal loads that can compromise both performance and longevity. The challenge is particularly acute in mobile devices and retrofit applications where space constraints are severe.
The fundamental challenge lies in balancing thermal management, optical efficiency, and driver integration within strict dimensional constraints while maintaining reliability.
This page brings together solutions from recent research—including integrated PCB mounting techniques, modular heat spreading architectures, sector-based light mixing approaches, and internal driver circuit integration. These and other approaches demonstrate practical ways to achieve miniaturization while preserving lighting performance and thermal stability.
1. Compact LED Lighting Apparatus with High-Density LED Array in Sub-5000 mm³ Package
EPISTAR CORPORATION, 2022
A compact LED lighting apparatus that provides high brightness from a small volume package. The lighting apparatus consists of a board with multiple LED light-emitting units mounted on it. These LEDs are enclosed in a package structure that has a volume of less than 5000 mm³ but still delivers a light intensity greater than 150 lumens.
2. Compact LED Lighting Apparatus with High-Intensity Output in Sub-5000 mm³ Package
EPISTAR CORPORATION, 2022
Lighting apparatus with high intensity and small size suitable for integration into compact consumer electronics and appliances. The lighting apparatus includes a board with multiple LED light-emitting units mounted on it. The LEDs are enclosed in a package structure with a volume of less than 5000 mm3. This small package size achieves a high light intensity greater than 150 lumens.
3. Compact LED Lighting Apparatus with High-Intensity Multi-Emitter Configuration in Minimal-Volume Package
EPISTAR CORPORATION, 2020
A compact and bright LED lighting apparatus that exceeds 150 lumens while having a small volume of less than 5000 mm3. The apparatus achieves high-intensity lighting in a compact package by using a board with multiple LED emitters and enclosing them in a minimal-volume package structure.
4. Compact LED Lighting Apparatus with High-Density Arrangement and Protective Enclosure
EPISTAR CORPORATION, 2020
Lighting apparatus with high intensity, small volume package, and high-efficiency LEDs. The apparatus includes a board with multiple small LEDs mounted on it and an enclosure that houses the LEDs. The enclosure has a volume of less than 5000 mm3 and protects the LEDs while maintaining high light output.
5. Low-Profile Luminaire with Integrated Heat Spreader and Sink Trim Plate for LED Downlighting
Lighting Science Group Corporation, 2020
Low-profile luminaire design for retrofit LED downlighting applications. The luminaire has a heat spreader, heat sink trim plate, and a light source mounted to the spreader. The spreader and sink are sized, shaped, and thermally coupled to effectively dissipate heat from the light source without requiring additional bulky heat-sinking components. This allows a compact form factor suitable for retrofitting into existing recessed light fixtures or junction boxes.
6. LED Module with Circular Sector Design for Mixed Light Emission
TRIDONIC JENNERSDORF GMBH, 2019
LED module for emitting mixed light, preferably white light, that can be used in lamps with small reflector sizes. The LED module has a circular light-emitting zone divided into flat sectors, like slices of a pie. Each sector can emit a different light spectrum. Phosphor can be added to the potting compound between the sectors to create white light. This allows producing a homogeneous mixed light from individual sector emissions. The circular sector design allows a small light-emitting zone suitable for small reflector lamps.
7. Flat-Panel LED Lighting Fixture with Integrated Driver Circuitry and Configurable Edge-Lit LED Arrays
UNITY OPTO TECHNOLOGY CO., LTD., 2019
A versatile, flat-panel LED lighting fixture that integrates the driver circuitry and allows multiple LED configurations to be driven separately for redundancy. The fixture has a frame that houses an LED panel. The panel has LEDs along the edges and a power circuit board that converts AC to DC within the frame. The circuitry is narrow and fits in a channel in the frame. The fixture can alternate between LED configurations by driving sets of LEDs separately.
8. Modular LED Lighting System with Radially Extending Modules and Central Hub
Outsight Pty Ltd, 2019
A high-power, energy-efficient lighting system for film and TV production that uses modular LED light sources. The system has a central hub connected to multiple radial modules. Each module contains an LED array, heat exchanger, and electronics. The modules extend radially and emit light through windows in a plane. This allows compact, modular construction with individual module replacement. An external frame connects the modules and hub. The modular design provides robust, lightweight, high-output lighting that can be expanded, replaced, or repaired easily.
9. Printed Circuit Board with Integrated Component Mounting for Reduced Z Height
MICROSOFT TECHNOLOGY LICENSING, LLC, 2019
Reducing the thickness of mobile devices by directly mounting protruding components like LED illumination and cameras inside the PCB. This is done by integrating PCB technologies to allow components to be mounted inside the PCB, reducing the Z height. Examples include PCBs with holes or apertures allowing components to protrude inside, or components with exposed connectors that can be soldered directly to the PCB.
10. Flat LED Lighting Fixture with Integrated Edge-Lit LED Panel and Internal Driver Circuitry
UNITY OPTO TECHNOLOGY CO., LTD., 2018
Flat LED lighting fixture with integrated internal driver circuitry for powering the LEDs, allowing a slim form factor and simplifying installation. The fixture has a thin frame containing an LED panel and power circuitry. The LED panel contains arrays of LEDs along the edges. The power circuitry includes drivers to convert AC power to DC for the LEDs. The circuitry is designed to fit within channels in the frame.
11. Compact Lighting Device with Multiple LEDs in Sub-5000 mm³ Enclosure
EPISTAR CORPORATION, 2018
A compact lighting device that provides high brightness in a small form factor using multiple LEDs. The device has a package structure enclosing the LEDs with a volume less than 5000 mm3. The encapsulated LEDs are mounted on a board. This enables a high lumen output of over 150 lumens from a very small package size, suitable for applications where intense lighting is needed in a confined space.
12. Ultrathin LED Light Engine with Integrated Heat Dissipation and Modular Assembly
SICHUAN SUNFOR LIGHT CO., LTD., 2018
Ultrathin LED light engine design with integrated heat dissipation, compact size and modularity for easy assembly. The light engine consists of a protective cover, a driving circuit board, an aluminum substrate, and LED modules. The circuit board is mounted on the aluminum substrate via a heat-conducting plate. The LED modules are mounted on the substrate and connect to the board with an insulated circuit. The cover reflects light and protects the components. The substrate and cover form a heat sink. This allows an ultrathin design with modular components while achieving good thermal management. The cover shape can be customized for different applications.
13. Compact LED Lighting Device with Offset Rotational LED Assemblies for Uniform Light Distribution
KONINKLIJKE PHILIPS N.V., 2018
LED lighting device for automotive applications that provides improved light distribution and small dimensions compared to prior LED lamps. The device comprises at least two LED assemblies with LED elements mounted in a specific arrangement relative to each other. The LED elements are arranged along a rotation axis with their planes parallel to the axis. The LED assemblies are offset and rotated around the axis to achieve uniform light distribution. This compact configuration allows the LED device to replace traditional filament bulbs in automotive lamps while maintaining the regulatory tolerance box for filament placement.
14. Compact LED Lighting Apparatus with High Intensity and Sub-5000 mm³ Volume
EPISTAR CORPORATION, 2018
A small form factor LED lighting apparatus with high intensity. The lighting apparatus has a volume less than 5000 mm3 and a light intensity greater than 150 lumens. The compact size makes it suitable for applications where space is limited. The apparatus achieves high brightness from multiple LEDs enclosed in a small package.
15. Miniature Linear LED Lighting Device with Parallel Filament Arrangement and Arc-Shaped Reflective Housing
LED-NER, 2018
Miniature adjustable linear LED lighting device with high color rendering index (CRI). The device has multiple LED filaments arranged inside a transparent outer container. The filaments are connected in parallel and emit light through a slot in an arc-shaped reflective housing. The device provides high CRI lighting in a compact form factor for applications like shop windows and shelves. The arc-shaped reflector creates a resonant cavity that repeatedly reflects the light back into the filament envelope to excite phosphors for better color rendering.
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The several methods for reducing LED lighting components are shown in these patents. Smaller and more potent lighting solutions are made possible by these inventions, which range from creating effective heat management systems to packing many LEDs into small containers.