A novel approach for RGB semiconductor LED-based backlighting system is developed to satisfy the requirements of the Project LUMENTILE funded by the European Commission, whose scope is to develop a luminous electronic tile that is foreseen to be manufactured in millions of square meters each year. This unconventionally large-area surface of uniform, high-brightness illumination requires a specific optical design to keep a low production cost, while maintaining high optical extraction efficiency and a reduced thickness of the structure, as imposed by architectural design constraints. The proposed solution is based on a light-guiding layer to be illuminated by LEDs in edge configuration, or in a planar arrangement. The light guiding slab is finished with a reflective top interface and a diffusive or reflective bottom interface/layer. Patterning is used for both the top interface (punctual removal of reflection and generation of a light scattering centers) and for the bottom layer (using dark/bright printed pattern). Computer-based optimization algorithms based on ray-tracing are used to find optimal solutions in terms of uniformity of illumination of the top surface and overall light extraction efficiency. Through a closed-loop optimization process, that assesses the illumination uniformity of the top surface, the algorithm generates the desired optimized top and bottom patterns, depending on the number of LED sources used, their geometry, and the thickness of the guiding layer. Specific low-cost technologies to realize the patterning are discussed, with the goal of keeping the production cost of these very large-area luminaries below the value of 100$/sqm.
LUMENTILE (LUMinous ElectroNic TILE) is a project funded by the European Commission with the goal of developing a luminous tile with novel functionalities, capable of changing its color and interact with the user. Applications include interior/exterior tile for walls and floors covering, high-efficiency luminaries, and advertising under the form of giant video screens. High overall electrical efficiency of the tile is mandatory, as several millions of square meters are foreseen to be installed each year. Demand is for high uniformity of the illumination of the top tile surface, and for high optical extraction efficiency. These features are achieved by smart light management, using a new approach based on light guiding slab and spatially selective light extraction obtained using both diffusion and/or reflection from the top and bottom interfaces of the optical layer. Planar and edge configurations for the RGB LEDs are considered and compared. A square shape with side length from 20cm to 60cm is considered for the tiles. The electronic circuit layout must optimize the electrical efficiency, and be compatible with low-cost roll-to-roll production on flexible substrates. LED heat management is tackled by using dedicated solutions that allow operation in thermally harsh environment. An approach based on OLEDs has also been considered, still needing improvement on emitted power and ruggedness.
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