Micro-LED amplitude control system
11343890 · 2022-05-24
Assignee
Inventors
- Antonio Lopez Julia (Vaals, NL)
- Ronald Johannes Bonne (Plainfield, IL, US)
- Zhi Hua Song (Palo Alto, CA, US)
Cpc classification
G09G3/2085
PHYSICS
G09G2320/0633
PHYSICS
G09G2320/045
PHYSICS
G09G3/2092
PHYSICS
G09G2360/18
PHYSICS
G09G3/2081
PHYSICS
G09G2320/064
PHYSICS
G09G3/3291
PHYSICS
G09G3/2014
PHYSICS
International classification
Abstract
A control system for an LED array relies on defining a first and a second group of separately addressed LED pixels, with the first group including pixels with an average current no less than the current at a Q point and a second group including pixels with an average current less than the current at a Q point. An amplitude signal provided to the first group of separately addressed LED pixels is selectively modulated, while providing a DC mode 100% duty cycle. An amplitude signal provided to the second group of separately addressed LED pixels is fixed, and a modulated duty cycle is provided.
Claims
1. A control method for a light emitting diode (LED) array, comprising: defining a first and a second group of separately addressed LED pixels, with the first group including pixels with an average current no less than the current at a Q point and a second group including pixels with an average current less than the current at the Q point, wherein the Q point is at a maximum external quantum efficiency (EQE) of an EQE versus current density curve for the LED array, the average current defined by an image to be provided by the LED array; selectively modulating, by a digital to analog converter (DAC), an amplitude of a first signal provided to LED pixels of the first group, the first signal further including a fixed duty cycle pulse width; and fixing, by a pulse width modulator (PWM), an amplitude of a second signal provided to LED pixels of the second group, the second signal further including a modulated duty cycle.
2. The control method for an LED array of claim 1, wherein the first signal is a direct current (DC) mode 100% duty cycle signal.
3. The control method for an LED array of claim 1, wherein the amplitude of the first signal is set at Iampi*D.sub.i, where Iampi is a current amplitude defined by the image and D.sub.i is the fixed duty cycle.
4. The control method for an LED array of claim 1, wherein the amplitude of the second signal is set at the Q point for the LED and the duty cycle is set at D.sub.i*Iampi/IQ, where Iampi is a current amplitude defined by the image, D.sub.i is a pixel duty cycle, and IQ is the current at the Q point of the EQE versus current density curve.
5. The control method for an LED array of claim 1, wherein additional groups of separately addressed LED pixels are determined, each group having a defined range of image amplitudes.
6. The control method for an LED array of claim 1, wherein the individually addressed LED pixels present the image provided by an image processing unit.
7. A control system for a light emitting diode (LED) array, comprising: first and second groups of individually addressed LED pixels, the first group including pixels with an average current no less than the current at a Q point of the individual LED and a second group including pixels with an average current less than the current at a Q point of the individual LED, the Q point is the maximum external quantum efficiency (EQE) of an EQE versus current curve for the individual LED, the average current defined by an image to be provided by the LED array; a digital to analog controller (DAC) module able to selectively adjust amplitude of signals; and a pulse width modulator acting with the DAC module to supply the first group of LED pixels with a first signal including a fixed duty cycle and a modulated amplitude, and the second group of LED pixels with a second signal with a fixed amplitude with the DAC and a modulated duty cycle.
8. The control system for an LED array of claim 7, wherein the first signal is a direct current (DC) mode 100% duty cycle signal.
9. The control system for an LED array of claim 7, wherein the DAC module further comprises multiple DAC units.
10. The control system for an LED array of claim 7, wherein the individually addressed LED pixels present the image provided by an image processing unit.
11. The control system for an LED array of claim 7, further comprising more than two groups of separately addressed LED pixels; and wherein the DAC module is able to selectively adjust an amplitude of a respective signal provided to each of the multiple groups of separately addressed LED pixels.
12. The control system for an LED array of claim 7, wherein the amplitude of the second signal is less than the amplitude of the first signal.
13. The control system for an LED array of claim 7, wherein the second signal has amplitude fixed to approach peak external quantum efficiency (EQE) and lower overall system power usage.
14. A control method for a light emitting diode (LED) array, comprising: providing a first and a second group of individually addressed LED pixels with the first group including pixels with an average current no less than the current at a Q point and a second group including pixels with an average current less than the current at the Q point, wherein the Q point is at a maximum external quantum efficiency (EQE) of an EQE versus current density curve for the LED array, the average current defined by an image to be provided by the LED array; supplying, by a pulse width modulator, the first group with a first signal that includes a fixed duty cycle and a modulated amplitude; and supplying, by a digital to analog converter, the second group with a second signal that includes a modulated duty cycle and a fixed amplitude signal.
15. The control method for an LED array of claim 14, wherein the first signal is a direct current (DC) mode 100% duty cycle signal.
16. The control method for an LED array of claim 14, wherein the individually addressed LED pixels present an image provided by an image processing unit.
17. The control method for an LED array of claim 14, wherein the second signal has amplitude decreased and duty cycle increased with respect to the first signal.
18. The control method for an LED array of claim 14, wherein the second signal has amplitude decreased and duty cycle increased with respect to the first signal to approach peak external quantum efficiency (EQE) and lower overall system power usage.
19. The control method for an LED array of claim 14, wherein additional groups of separately addressed LED pixels are determined, each group having a defined, different signal amplitude.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(9) Various techniques, devices, or systems can be used to improve overall power efficiency for a micro-LED array system. For example, in some embodiments respective subsets of high lumen pixels can be driven using a different PWM electrical current amplitude. Yet another technique involves defining multiple amplitude steps appropriate for various pixel groupings. In addition to modifying LED pixel operation, optimum operating current for minimizing total power losses can be shifted after accounting for pixel driver and interconnect design. Use of these techniques, devices or systems can provide a lower minimum average current due to smaller amplitude and effectively increase the dynamic current range of the array.
(10) Some of these improved power efficiency techniques are contrasted with respect to graph 100 of
(11) As previously noted, improved power efficiency can be realized in one embodiment by having a subset of high lumen pixels in a pixel matrix be driven using a different PWM current amplitude than another subset of pixels of the array. In order to accurately present an image, the operation mode for the highest lumen pixels (a duty cycle of 100%) cannot be changed. High lumen pixels need to run in DC mode with the maximum amplitude or with maximum image amplitude. However, for pixels with a duty cycle less than one, it is possible to increase the duty cycle and reduce the amplitude while still maintaining the same average current required by image data. Since the amplitude decreases, the current density can move towards the Q point 110 from the right side of curve 106 of
(12) In some embodiments, the amplitude of each pixel individually may be adjusted towards the Q point 110 in
(13) 1) For pixels with an average current no less than the current at the Q point, or IQ: the amplitude can be modulated to I.sub.ampi×D.sub.i with the duty cycle fixed (e.g. at 80%, 90 or 100%, a lesser percentage, or some percentage therebetween). In some embodiments, the duty cycle can be one (1), or DC mode. This is the maximum achievable modulation towards the Q point.
2) For pixels with an average current less than IQ: the amplitude can be fixed at IQ because further decreasing it to below IQ would lower the EQE. The duty cycle becomes D.sub.i×I.sub.ampi/IQ.
(14) In some embodiments, modifications to the system, including but not limited to changes in pixel driver and interconnects, may be used to shift the optimum operating current for the minimum total losses. For instance, changing the MAIM signal to DC current of I.sub.ampi×D.sub.i will cause the resistive losses of interconnects to reduce from I.sub.ampi.sup.2×D.sub.i to I.sub.ampi.sup.2×D.sub.i.sup.2. This also means although the LED EQE peaks at the Q point in
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(16) As seen in flow chart 120, in step 122 a first group of pixels with an average current no less than the current at the Q point is identified. In step 124, a second group of pixels with an average current less than the current at a Q point is identified. In step 126 a selectively modulated amplitude signal is provided to the first group of pixels, such that a fixed duty cycle of pulse width modulated signals is provided. In step 128, an amplitude signal is fixed to provide to the second group of pixels a modulated duty cycle of pulse width modulated signals. This procedure can be repeated as necessary.
(17) Another implementation with individual, stepless pixel amplitude adjustment is described with respect to
(18) The following Table 1 illustrates specific example values for stepless pixel amplitude adjustment for the system illustrated with respect to
(19) TABLE-US-00001 TABLE I Modulated amplitude, Image Duty I.sub.ampmod (normalized to Modulated duty Cycle, D.sub.i image amplitude) cycle, D.sub.mod D.sub.i ≥ 35% D.sub.i 100% D.sub.i < 35% 0.35 D.sub.i/0.35
(20) Since the current is normalized to the image amplitude, the normalized average current in Equation (1) becomes 1*D.sub.i, equaling to D.sub.i. Therefore, as seen in
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(22) As seen in flow chart 220, in step 222 an IQ.sub.n setpoint is identified for pixels having a duty cycle. In step 224, when the average current D.sub.i for a pixel is above the IQn setpoint, modulating amplitude is set to a normalized amplitude of D.sub.i with a 100% modulated duty cycle. In step 226, when the average current D.sub.i for a pixel is below the IQ.sub.n setpoint, modulating amplitude is fixed and the duty cycle is set to D.sub.i divided by the IQ.sub.n. This procedure can be repeated as necessary.
(23) An alternative approach can be based on defining multiple amplitude steps between the image amplitude, corresponding to M point 114 or N point 116 in
(24) In one example, modulation of each pixel group can fall into one of two categories:
(25) 1) For a group whose brightest pixels have an average current no less than the optimum current IQ the amplitude can be modulated to I.sub.ampi×D.sub.imax, with D.sub.imax being the maximum image duty cycle of that group. Accordingly, the duty cycle of each pixel is adjusted to D.sub.i/D.sub.imax, with D.sub.i being the image duty cycle of each pixel.
2) For a group whose brightest pixels have an average current less than IQ: the amplitude can be fixed at IQ. Accordingly, the duty cycle of each pixel is adjusted to D.sub.i×I.sub.ampi/IQ, with D.sub.i being the image duty cycle of each pixel.
(26) Since multiple group modulation relies on limited levels for amplitude modulation, computation may be simpler than that described with respect to
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(28) TABLE-US-00002 TABLE 2 Modulated amplitude, Group Image Duty I.sub.ampmod (normalized to Modulated duty Number Cycle, D.sub.i image amplitude) cycle, D.sub.mod 1 75% < D.sub.i ≤ 100% 1 D.sub.i 2 50% < D.sub.i ≤ 75% 0.75 D.sub.i/0.75 3 25% < D.sub.i ≤ 50% 0.5 D.sub.i/0.5 4 1% < D.sub.i ≤ 25% 0.35 D.sub.i/0.35
(29) As is apparent, Groups 1 through 3 have the same duty cycle increment of 25%, while group 4 has an increment of 24%. For group 1, 2 and 3, the modulated amplitude is the average electrical current of the brightest pixel within the group, being 1, 0.75 and 0.5, respectively. The respective modulated duty cycle is the average current D.sub.i divided by the modulated amplitude, being D.sub.i, D.sub.i/0.75 and Di/0.5. For group 4, because the IQ.sub.n value of 0.35 is bigger than the average current of the brightest pixel, 0.25, the amplitude is set at 0.35. The duty cycle becomes D.sub.i/0.35. This is graphically illustrated by
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(31) As seen in flow chart 320, in step 322 multiple groups of pixels having a duty cycle within a defined range are identified. In step 322, the brightest pixels have a duty cycle set at 100% for a distinct modulated amplitude. In step 324, for each group of pixels, the duty cycle is set within the defined range to be D.sub.i divided by the IQ.sub.n. This procedure can be repeated as necessary.
(32) In the foregoing described embodiments, intensity can be separately controlled and adjusted by setting appropriate pulse widths for each LED pixel using a suitable lighting logic and control module and/or PWM module. This is illustrated with respect to
(33) Processing modules that facilitate efficient power usage in the system 400 are illustrated in
(34) The term module, as used herein, may refer to electrical and/or electronic components disposed on individual circuit boards that may be soldered to one or more electronics boards. The term module may, however, also refer to electrical and/or electronic components that provide similar functionality, but which may be individually soldered to one or more circuit boards in a same region or in different regions.
(35) As will be appreciated, in some embodiments a modulation computation may be done by the control module 402 through directly generating a modulated image. Alternatively, a standard image file can be processed or otherwise converted to provide modulation. Image data that mainly contains PWM duty cycle values is processed for all pixels in image processing module 404. Since amplitude is a fixed value or rarely changed value, amplitude related commands can be given separately through a digital interface, such as a wired or wireless interface previously discussed. The control module 402 interprets digital data, which can then be used by PWM generator 412 to generate modulated PWM signals, D.sub.mod, for pixels, and by DAC module 410 to generate the control signals for obtaining the required current source amplitude. Next, the modulated amplitude and PWM duty cycle are coupled to the pixel matrix 420 that contains m pixel units. Each pixel unit is composed of the micro-LED, a PWM switch with the modulated duty cycle, and a current source with the modulated amplitude.
(36) In some embodiments, the DAC module 410 may contain multiple DAC units, with the total number of n and no more than the total number of pixels, m. Modulation resolution or steps determine the number of bits needed for operation of the DAC module 410. Finer resolution or increasing number of amplitude steps can require more bits and a larger DAC module. For instance, the amplitude partition method illustrated with respect to
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(38) In operation, system 500 can accept image or other data from a vehicle or other source that arrives via the SPI interface 514. Successive images or video data can be stored in an image frame buffer 510. If no image data is available, one or more standby images held in a standby image buffer 511 can be directed to the image frame buffer 510. Such standby images can include, for example, an intensity and spatial pattern consistent with legally allowed low beam headlamp radiation patterns of a vehicle, or default light radiation patterns for architectural lighting or displays.
(39) In operation, pixels in the images are used to define response of corresponding LED pixels in the active, with intensity and spatial modulation of LED pixels being based on the image(s). To reduce data rate issues, groups of pixels (e.g. 5×5 blocks) can be controlled as single blocks in some embodiments. In some embodiments, high speed and high data rate operation is supported, with pixel values from successive images able to be loaded as successive frames in an image sequence at a rate between 30 Hz and 100 Hz, with 60 Hz being typical. Pulse width modulation can be used to control each pixel to emit light in a pattern and with an intensity at least partially dependent on the image held in the image frame buffer 510.
(40) In some embodiments, the system 500 can receive logic power via V.sub.dd and V.sub.ss pins. An active matrix receives power for LED array control by multiple VLED and V.sub.Cathode pins. The SPI 514 can provide full duplex mode communication using a master-slave architecture with a single master. The master device originates the frame for reading and writing. Multiple slave devices are supported through selection with individual slave select (SS) lines. Input pins can include a Master Output Slave Input (MOSI), a Master Input Slave Output (MISO), a chip select (SC), and clock (CLK), all connected to the SPI interface 514. The SPI interface 514 connects to an address generator, frame buffer, and a standby frame buffer. Pixels can have parameters set and signals or power modified (e.g. by power gating before input to the frame buffer, or after output from the frame buffer via pulse width modulation or power gating) by a command and control module. The SPI interface 514 can be connected to an address generation module 518 that in turn provides row and address information to the active matrix 520. The address generator module 518 in turn can provide the frame buffer address to the frame buffer 510.
(41) In some embodiments, the command and control module 516 can be externally controlled via an I.sup.2C serial bus 512. A clock (SCL) pin and data (SDA) pin with 7-bit addressing can be supported. The command and control module 516 can include a digital to analog converter (DAC) and two analog to digital converters (ADC). These are respectively used to set V.sub.bias for a connected active matrix, help determine maximum V.sub.f, and determine system temperature. Also connected are an oscillator (OSC) to set the pulse width modulation oscillation (PWMOSC) frequency for the active matrix 520. In one embodiment, a bypass line is also present to allow address of individual pixels or pixel blocks in the active matrix for diagnostic, calibration, or testing purposes. The active matrix 520 can be further supported by row and column select that is used to address individual pixels, which are supplied with a data line, a bypass line, a PWMOSC line, a V.sub.bias line, and a V.sub.f line.
(42) As will be understood, in some embodiments the described circuitry and active matrix LEDs 520 can be packaged and optionally include a submount or printed circuit board connected for powering and controlling light production by the semiconductor LED. In certain embodiments, the printed circuit board can also include electrical vias, heat sinks, ground planes, electrical traces, and flip chip or other mounting systems. The submount or printed circuit board may be formed of any suitable material, such as ceramic, silicon, aluminum, etc. If the submount material is conductive, an insulating layer is formed over the substrate material, and the metal electrode pattern is formed over the insulating layer. The submount can act as a mechanical support, providing an electrical interface between electrodes on the LED and a power supply, and also provide heat sinking.
(43) In some embodiments, the active matrix 520 can be formed from light emitting elements of various types, sizes, and layouts. In one embodiment, one or two dimensional matrix arrays of individually addressable light emitting diodes (LEDs) can be used. Commonly N×M arrays where N and NI are respectively between two and one thousand can be used. Individual LED structures can have a square, rectangular, hexagonal, polygonal, circular, arcuate or other surface shape. Arrays of the LED assemblies or structures can be arranged in geometrically straight rows and columns, staggered rows or columns, curving lines, or semi-random or random layouts. LED assemblies can include multiple LEDs formed as individually addressable pixel arrays are also supported. In some embodiments, radial or other non-rectangular grid arrangements of conductive lines to the LED can be used. In other embodiments, curving, winding, serpentine, and/or other suitable non-linear arrangements of electrically conductive lines to the LEDs can be used.
(44) In some embodiments, arrays of microLEDs (μLEDs or uLEDs) can be used. uLEDs can support high density pixels having a lateral dimension less than 100 μm by 100 μm. In some embodiments, uLEDs with dimensions of about 50 μm in diameter or width and smaller can be used. Such uLEDS can be used for the manufacture of color displays by aligning, in close proximity, uLEDs comprising red, blue, and green wavelengths. In other embodiments, uLEDS can be defined on a monolithic gallium nitride (GaN) or other semiconductor substrate, formed on segmented, partially, or fully divided semiconductor substrate, or individually formed or panel assembled as groupings of uLEDs. In some embodiments, the active matrix 520 can include small numbers of uLEDs positioned on substrates that are centimeter scale area or greater. In some embodiments, the active matrix 520 can support uLED pixel arrays with hundreds, thousands, or millions of LEDs positioned together on centimeter scale area substrates or smaller. In some embodiments, uLEDS can include LEDs sized between 30 microns and 500 microns. In some embodiments, each of the light emitting pixels in the light emitting pixel array can be positioned at least 1 millimeter apart to form a sparse LED array. In other embodiments sparse LED arrays of light emitting pixels can be positioned less than 1 millimeter apart and can be spaced apart by distances ranging from 30 microns to 500 microns. The LEDs can be embedded in a solid or a flexible substrate, which can be at least in part transparent. For example, the light emitting pixel arrays can be at least partially embedded in glass, ceramic, or polymeric materials.
(45) Light emitting matrix pixel arrays, such as discussed herein, may support applications that benefit from fine-grained intensity, spatial, and temporal control of light distribution. This may include, but is not limited to, precise spatial patterning of emitted light from pixel blocks or individual pixels. Depending on the application, emitted light may be spectrally distinct, adaptive over time, and/or environmentally responsive. The light emitting pixel arrays may provide pre-programmed light distribution in various intensity, spatial, or temporal patterns. The emitted light may be based at least in part on received sensor data and may be used for optical wireless communications. Associated optics may be distinct at a pixel, pixel block, or device level. An example light emitting pixel array may include a device having a commonly controlled central block of high intensity pixels with an associated common optic, whereas edge pixels may have individual optics. Common applications supported by light emitting pixel arrays include video lighting, automotive headlights, architectural and area illumination, street lighting, and informational displays.
(46) Light emitting matrix pixel arrays may be used to selectively and adaptively illuminate buildings or areas for improved visual display or to reduce lighting costs. In addition, light emitting pixel arrays may be used to project media facades for decorative motion or video effects. In conjunction with tracking sensors and/or cameras, selective illumination of areas around pedestrians may be possible. Spectrally distinct pixels may be used to adjust the color temperature of lighting, as well as support wavelength specific horticultural illumination.
(47) Street lighting is an application that may benefit from use of light emitting pixel arrays. A single light emitting array may be used to mimic various street light types, allowing, for example, switching between a Type I linear street light and a Type IV semicircular street light by appropriate activation or deactivation of selected pixels. In addition, street lighting costs may be lowered by adjusting light beam intensity or distribution according to environmental conditions or time of use. For example, light intensity and area of distribution may be reduced when pedestrians are not present. If pixels of the light emitting pixel array are spectrally distinct, the color temperature of the light may be adjusted according to respective daylight, twilight, or night conditions.
(48) Light emitting arrays are also suited for supporting applications requiring direct or projected displays. For example, warning, emergency, or informational signs may all be displayed or projected using light emitting arrays. This allows, for example, color changing or flashing exit signs to be projected. If a light emitting array is composed of a large number of pixels, textual or numerical information may be presented. Directional arrows or similar indicators may also be provided.
(49) Vehicle headlamps are a light emitting array application that requires large pixel numbers and a high data refresh rate. Automotive headlights that actively illuminate only selected sections of a roadway can used to reduce problems associated with glare or dazzling of oncoming drivers. Using infrared cameras as sensors, light emitting pixel arrays activate only those pixels needed to illuminate the roadway, while deactivating pixels that may dazzle pedestrians or drivers of oncoming vehicles. In addition, off-road pedestrians, animals, or signs may be selectively illuminated to improve driver environmental awareness. If pixels of the light emitting pixel array are spectrally distinct, the color temperature of the light may be adjusted according to respective daylight, twilight, or night conditions. Some pixels may be used for optical wireless vehicle to vehicle communication.
(50) An LED light module can include matrix LEDS, alone or in conjunction with primary or secondary optics, including lenses or reflectors. To reduce overall data management requirements, the light module can be limited to on/off functionality or switching between relatively few light intensity levels. Full pixel level control of light intensity is not necessarily supported.
(51) In operation, pixels in the images are used to define response of corresponding LED pixels in the pixel module, with intensity and spatial modulation of LED pixels being based on the image(s). To reduce data rate issues, groups of pixels (e.g. 5×5 blocks) can be controlled as single blocks in some embodiments. High speed and high data rate operation is supported, with pixel values from successive images able to be loaded as successive frames in an image sequence at a rate between 30 Hz and 100 Hz, with 60 Hz being typical. In conjunction with a pulse width modulation module, each pixel in the pixel module can be operated to emit light in a pattern and with intensity at least partially dependent on the image held in the image frame buffer.
(52) Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims. It is also understood that other embodiments of this invention may be practiced in the absence of an element/step not specifically disclosed herein. In those embodiments supporting software controlled hardware, the methods, procedures, and implementations described herein may be realized in a computer program, software, or firmware incorporated in a computer-readable medium for execution by a computer or processor. Examples of computer-readable media include electronic signals (transmitted over wired or wireless connections) and computer-readable storage media. Examples of computer-readable storage media include, but are not limited to, a read only memory (ROM), a random access memory (RAM), a register, cache memory, semiconductor memory devices, magnetic media such as internal hard disks and removable disks, magneto-optical media, and optical media such as CD-ROM disks, and digital versatile disks (DVDs).