Design of blue LEDs array with high optical power

Abstract

In this paper, an array of blue LEDs with high optical power was presented and discussed. Optical of the novel design was completed with the help of running simulation in TracePro to predict the performance of the module. 36 Cree XP-E blue LEDs with a square reflector were used in the novel design. Optical simulation obtained from TracePro showed that the total optical power of the LED array could reach 16.83W. To verify the simulation results, Aluminum PCB, Copper PCB and Aluminum square reflector have been made respectively. Firstly, 36 Cree XP-E blue LEDs with small-pitch were fixed on each PCB, then; an Aluminum square reflector was assembled on each PCB. This optical module was installed on a radiator and tested. The optical output power of sample 1 used Aluminum PCB and Aluminum reflector and sample 2 used Copper PCB and Aluminum reflector was 8.126W and 9.445W at 2A, respectively. It could be observed that the optical output power of sample 2 was higher than that of sample 1. It could be attributed to the better thermal dispersion performance of Copper. In order to improve the light reflectivity and reduce the loss of light, ultrathin silver was coated on the Aluminum reflector by electron beam evaporation. The optical output power of sample 3 used Copper PCB and silver-plated Aluminum reflector was 12.541W at 2A. A uniform square spot with high optical power was obtained.