Let $\mathcal L$ be a sub-lattice of $\mathcal P(X)$, where $X$ is a finite set.
Denote by $\mathcal I(\mathcal L)$ the set of union-irriducible elements of $\mathcal L$ (i.e. $A\in \mathcal I(\mathcal L)$ iff $A\in\mathcal L$ and it is not possible to write $A$ as a union of other elements of $\mathcal L$).
Is it true that $card(\mathcal I(\mathcal L))\leq card(X)$ ?
Edit. An important point is that $\mathcal I(\mathcal P (X))=X$. Therefore it is possible to restate the question in general terms as follows: let $\mathcal L'$ be a finite distributive lattice and let $\mathcal L$ be a sub-lattice of $\mathcal L'$, is it true that $card (\mathcal I(\mathcal L)) \leq card (\mathcal I(\mathcal L'))$ ?
Yes, $\operatorname{card}(\mathcal I(\mathcal L))\le\operatorname{card}(X)$. For each $x\in\bigcup\mathcal L$, let $M_x=\bigcap\{A\in\mathcal L:x\in A\}$, the least element of $\mathcal L$ containing $x$. Clearly $M_x$ is join-irreducible. These are the only join-irreducible elements: if $A\in\mathcal L$ then $A=\bigcup\{M_x:x\in A\}$, so $A$ is not join-irreducible unless $A=M_x$ for some $x\in A$.
More generally, suppose $\mathcal L$ is a sub-lattice of a finite distributive lattice $\mathcal L'$, and let $1_\mathcal L$ be the greatest element of $\mathcal L$. For each $a\in\mathcal I(\mathcal L')$ with $a\le1_\mathcal L$, define $\hat a=\bigwedge\{x\in\mathcal L:a\le x\}$; then $a\le\hat a\in\mathcal I(\mathcal L)$.
For any $b\in\mathcal L$ we have $b=\bigvee\{a:a\in\mathcal I(\mathcal L'),\ a\le b\}=\bigvee\{\hat a:a\in\mathcal I(\mathcal L'),\ a\le b\}$; if $b$ is join-irreducible in $\mathcal L$, then $b=\hat a$ for some $a\in\mathcal I(\mathcal L')$. Hence $$\mathcal I(\mathcal L)=\{\hat a:a\in\mathcal I(\mathcal L'),\ a\le1_\mathcal L\}$$ and so $$\operatorname{card}(\mathcal I(\mathcal L))\le\operatorname{card}(\{a\in\mathcal I(\mathcal L')):a\le1_\mathcal L\})\le\operatorname{card}(\mathcal I(\mathcal L')).$$