Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
LEDsmagazine.com
Controls
Dimming LEDs P.27
Interconnects
Solder-less sockets
speed assembly P.39
Manufacturing
TECHNOLOGY AND APPLICATIONS OF LIGHT EMITTING DIODES SPC strategy for
LED lines P.49
Arena
Lighting
SSL shines on
basketball court P.7
Dimmable
Dimmable
Dimmable
July/August
2013
features
columns/departments
23 THE LED SHOW PREVIEW Maury Wright
Conference will include LED technology and 2 COMMENTARY Maury Wright
standards updates Less may become more in
SSL product lifetime
and SPC
17 FUNDING + PROGRAMS
Zhaga expands certification
57 DESIGN FORUM David Zhang, Texas Instruments
Dimming multiple LED strings enables color-tunable
program, adds GLA liaison
USDA and SETi document UV LED
luminaires benefits for fresh produce
DOE awards $10.1 million in
60 LAST WORD Charlie Szoradi, Independence LED
Myth busting as it relates to LED tubes
new research awards
MSSLC will host annual
meeting in September
EPA and Soraa spar on lamp efficacy
T
SENIOR ILLUSTRATOR Christopher Hipp
AUDIENCE DEVELOPMENT Debbie Bouley
imes change quickly in the solid-state also covered in my column from the previous
lighting (SSL) world. Just two years ago, issue (ledsmagazine.com/features/10/6/3).
LED and lighting manufacturers were mak- He simply said long life doesnt matter in
ing hyperbolic claims of 50,000100,000- most applications, and used 20,00025,000 EDITORIAL OFFICES PennWell Corporation,
LEDs Magazine
hour product lives and many poorly designed hours to characterize long life. 98 Spit Brook Road, LL-1
SSL products were failing very early. Now a Khosla made his point with a simple Nashua, NH 03062-5737
Tel: +1 603 891 0123
maturing industry can reliably deliver light- image. He showed a photo of a phone that we Fax: +1 603 891 0574
ing products with such long life, but should may have used 25,000 hours ago and asked if www.ledsmagazine.com
they? Ive become increasingly convinced anyone still wanted to use that phone today. SALES OFFICES
SALES MANAGER Kelly Barker
that, while exceptions exist, the industry LEDs are going to enable amazing new form
(US EAST COAST) kellybarker@Pennwell.com
needs to focus on 10,00015,000-hour life- factors and features in lighting products. Tel. +1 603 891 9186
times for many mainstream products. So even if someone installs a 50,000-hour SALES MANAGER Allison OConnor
(US WEST COAST) allison@jagmediasales.com
Dont misunderstand. I applaud the devel- product today, they are apt to change it long
Tel. +1 480 991 9109
opments of the last few years. The LED indus- before end of life comes. SALES MANAGER Jim Ajayi
try has embraced LM-80 testing and the TM-21 If we reduce the expectation to 10,000 (EUROPE) jima@pennwell.com
Tel. +44(0) 199 265 6657
methodology to project component life. Prod- 15,000 hours, what is the impact? I dont
SALES MANAGER Holger Gerisch
uct developers have learned to implement ther- have all of the answers. But we could use (FRANCE/GERMANY/ holgerg@pennwell.com
mal and driver technology to ensure that SSL fewer LEDs driven harder and slash upfront AUSTRIA/SWITZERLAND) Tel: +49(0) 885 6802 0228
systems deliver on long-life potential. cost. Maybe we really dont need such com- SALES MANAGER Manami Konishi
(JAPAN) konishi-manami@ics-inc.co.jp
Still, in many cases, the industry will be plex thermal management in all products. Tel: +81 3 3219 3641
better off with a more moderate expecta- Simpler thermals could lower costs and yield SALES MANAGER Mark Mak
tion of lifetime. We can ensure a more robust more attractive products. (CHINA & HONG KONG) markm@actintl.com.hk
Tel: +852 2838 6298
ongoing lighting economy with regularly Obviously, my stance doesnt apply every-
SALES MANAGER Diana Wei
refreshed product lines and retrofitted instal- where. Industrial lighting that burns 24 hours (TAIWAN) diana@arco.com.tw
lations that still deliver all of the energy-effi- a day and is rarely retrofitted warrants prod- Tel: +886 2 2396 5128 ext: 270
ciency promises of LED technology. ucts designed for long lifetimes. There is a SALES MANAGER Young Baek
(KOREA) ymedia@chol.com
Now I cant claim this revelation as original light fixture on a high ceiling in a basement Tel: +82 2 2273 4818
thinking. Ive heard industry insiders make stairwell at my mothers house that will get CORPORATE OFFICERS
CHAIRMAN Frank T. Lauinger
similar points, so credit where credit is due. an expensive Philips L-Prize lamp, which will PRESIDENT AND CEO Robert F. Biolchini
Last year at the Street and Area Lighting probably last 50,000 hours, installed when it CHIEF FINANCIAL OFFICER Mark C. Wilmoth
Conference, Mark Hand, director of new next burns out. Clearly, street lights arent ret- TECHNOLOGY GROUP
products and technology at Acuity Brands, rofitted often and long life is a huge part of pro- SENIOR VICE PRESIDENT Christine A. Shaw
& PUBLISHING DIRECTOR
discussed how LED products are essentially jected payback.
SUBSCRIPTIONS: For subscription inquiries:
over-specified for most applications (leds ___ For many applications, less may be more. Tel: +1 847 559 7330;
magazine.com/features/9/12/11). Ironically, Even office spaces are often retrofitted more Fax: +1 847 291 4816;
e-mail: led@omeda.com;
he presented at an event where long life quickly than the lifetimes that are common- ledsmagazine.com/subscribe
may make sense. But Hands point was that place with new SSL products. So great job to
We make portions of our subscriber list available to carefully screened
specifiers can manage the cost of products by the industry, but lets rethink the strategy in companies that offer products and services that may be important for
your work. If you do not want to receive those offers and/or information
being realistic and only demanding long life, many cases. via direct mail, please let us know by contacting us at List Services
LEDs, 98 Spit Brook Road LL-1, Nashua, NH 03062.
or other premium features such as high CRI,
Copyright 2013 PennWell Corp (ISSN 2156-633X). All rights
when justified by the application. reserved. Contents of this publication may not be reproduced in any
form without prior written consent of Publishers.
Venture capitalist Vinod Khosla took a Maury Wright, EDITOR
stronger stance in a Lightfair keynote that I mauryw@pennwell.com
ADVERTISERS index
American Bright Optoelectronics .................10 Indium Corp. ...............................................25 Seoul Semiconductor ..................................26
ASK SRL .....................................................14 Intertek .......................................................16 Shanxi Guangyu Led Lighting Co. Ltd. .........18
Autec Power Systems..................................31 Inventronics (Hangzhou) Inc. .......................38 Shenzhen Refond
Optoelectronics Co. Ltd. ...........................20
Beautiful Light Technology Corporation........13 IOTA Engineering .........................................30
Shin Etsu Silicones of America Inc. .............41
Cooledge Lighting Inc....................................9 Lauren Manufacturing .................................36
Signcomplex Ltd. ........................................37
E-Lite Optotech Co. Ltd. ..............................42 Ledlink Optics Inc. ......................................15
The Bergquist Company ................................6
EBM-Papst Inc. .............................................5 Lumens Co. Ltd. .........................................19
The Korean Consulate General....................36
Ellsworth Adhesives ....................................55 Matrix Lighting Limited, Hong Kong ...........CV2
Underwriters Laboratories .........................CV4
G-S Plastic Optics .......................................12 MBN GmbH.................................................21
Ushio America Inc. ......................................55
Global Lighting Technologies .......................11 Mean Well Usa Inc. .....................................34
Zhejiang Baikang Technological Co. Ltd. ........3
Henkel ........................................................22 Orb Optronix................................................43
IIDEX/Neocon Canada ................................53 Proto Labs Inc. ...........................................33
Indice Ecotech ............................................24 Sapa Extrusions..........................................29
In order to reach the desired lumen values in a small form factor, active cooling may be required
to effectively dissipate the heat produced by the LED components. Active cooling technology
offers thermal capabilities with inaudible noise that is superior to passive heat sinks and raises
performance while reducing the size of the lighting fixture. With an industry-leading German-
engineered compact fan and an American-designed assembly, ebm-papst can provide the most
reliable solution for your LED cooling problems.
To find out more about custom Active Cooling Solutions, visit info.ebmpapst.us/ActiveCooling
____________________
The engineers choice
9th Replacement
3rd Replacement
5th Replacement
12th Replacement
www.bergquistcompany.com 1.800.347.4572
9 5 2 . 8 3 5 . 2 3 2 2 f a x 9 5 2 . 8 3 5 . 0 4 3 0
1 8 9 3 0 We s t 7 8 t h S t r e e t C h a n h a s s e n , M i n n e s o t a 5 5 3 1 7 Thermal Materials Thermal Substrates Fans and Blowers
news views
ARENA LIGHTING
GE supplies Albeo
high-bay LEDs for Weber
State Dee Events Center
GE Lighting announced that its Albeo business unit,
acquired in November 2012 (ledsmagazine.com/
news/9/11/18), has supplied 80 ABHX-Series solid-state
_________
lighting (SSL) luminaires to Weber State University in
Odgen, UT to light the campus Dee Events Center. The LED-
based high-bay fixtures will save the university $40,000 each
year in energy costs, and reduce maintenance cost as well
especially given that the lights are very difficult to reach.
Lighting sports venues is one of the last applications
where LED lighting has made headway. There are many
instances of major sports venues using SSL for decorative
or entertainment purposes, or to light areas such as con-
cessions or concourses. The Weber State project, however, fixtures that can deliver the requisite light levels. Matur-
may be the most significant use of SSL products in lighting ing LED technology has now made the technology feasible
a playing surface. in lighting playing surfaces. And LEDs will never have the
The roadblock to LED usage in sports-venue lighting has restrike problem that plagued the NFL Super Bowl after a
been the light output required and the cost and weight of minor power outage this past February.
energy. Now thats something we welcome Chow also said a single LED
and our teams and fans can appreciate. HEMT could control multi- Gate HEMT
MORE: ledsmagazine.com/news/10/7/1 ple LEDs on one chip. GND
The project utilized a
RESEARCH GaN substrate and realized an LED that discussions, system or IC partition choices,
matches the light density of standard GaN and sometimes debate.
RPI integrates LED emitters LEDs being manufactured in volume today. The study entitled Monolithic integration
with on-chip electronics The research team compares the devel- of light-emitting diodes and power metal-
Researchers at the Rensselaer Polytechnic opment with the evolution of transistors oxide semiconductor channel high-electron-
Institute (RPI) Smart Lighting Engineering to dense ICs in the silicon semiconductor mobility transistors for light-emitting power
Research Center (ERC) have integrated a world, with Chow calling the device a light- integrated circuits in GaN on sapphire sub-
power transistor in gallium-nitride (GaN) emitting integrated circuit (LEIC). strate has been published in the scientific
layers along with an LED structure. The RPI The implication is LEDs that might have journal Applied Physics Letters.
research is focused on adding functionality complex integrated functions ranging from MORE: ledsmagazine.com/news/10/6/11
Cooledge
X
When it comes to developing your next LED luminaire,
Cooledge redefines conventional wisdom.
Lets start thinking outside of the box.
What if . . .
your light source was flexible?
you could use any material you choose?
you didnt have to deal with heat?
_________________
shopping experience for customers. The unique environments for our customers
grocer is replacing 64W halogen lighting throughout the stores.
with GE Energy Smart 17W LED PAR38 The grocer plans to complete the
Retail lamps, and has already installed company-wide retrofit this year. Prior to
17,000 lamps. the LED transition, a typical store using
The Fresh Market initiated the LED 312 lamps would consume 107,800 kWh
project in 2011 working with distributor annually. That number drops to 28,600
Illuminating Technologies to evaluate kWh with the LED lamps in place.
potential LED-based replacements for The LED transition is also leading
its halogen lighting. The management to secondary benefits in energy and
team wanted to save energy, but also maintenance savings. As we started to
wanted to preserve the ambiance and replace the old halogen bulbs with LED
improve the quality of lighting on the lamps, we realized we were taking the
products. The European-style markets first stage of heat out of the building,
feature an open-air layout with prom- said Poole. As a result, we dont have
inent produce bins, meat and cheese to run our HVAC systems as much
cases, and bakery goods. because less heat is generated from
The grocer sought to test whole-store other equipment in the building. Add to
retrofits from the start of the project. We that the anticipated time savings from
didnt just replace ten or fifteen lights in our store managers replacing bulbs
one area of the store we actually asked LEDs have a 50,000-hour life compared
suppliers to provide us with three hundred to halogens 3,000-hour life and there
______________
lamps for a complete store retrofit so our is very low risk with this project. _____________
executives could properly evaluate the MORE: illuminationinfocus.com/news/4/6/2
The team has thus far demonstrated the conversion of blue LED
light into red light using silicon particles that are smaller than 5
nm. They believe that they can develop yellow and green particles
in short order. The combination of the three and blue LED emitters
could deliver a spectrum near that of sunlight.
MORE: ledsmagazine.com/news/10/6/11
BUSINESS
________________________
___________________________________
LEDsmagazine.com
_________
news+views
trol of devices such as the thermostat so cus- PACKAGED LEDS In a news
tomers can monitor and minimize energy release, TSMC
usage. Now Comcast will add adaptive light- TSMC announces new said that the
ing to the service. packaged LEDs and COBs, TH3 LED is
With Osram Sylvania, we are bringing and China market plans capable of oper-
innovative lighting solutions that integrate TSMC (Taiwan Semiconductor ating at power levels to 3W,
with the Xfinity Home platform and pro- Manufacturing Company) SSL (Solid although the companys website indicates a
vide home control and green technology fea- State Lighting) has announced new LEDs, maximum 2W rating. The product is offered
tures to our customers, said Mitch Bowling, which it displayed at the 2013 Guangzhou in CCT ranging from 2700K to 5700K with all
senior vice president and general manager of International Lighting Exhibition from June but the highest CCT models having a mini-
new businesses for Comcast Cable. Home 912, 2013. A spokesperson confirmed with mum CRI of 80. At 350 mA binning current
automation is a growing trend that takes the new announcement that the company will and 5700K, the LEDs offer efficacy rang-
complex ideas and turns them into simple be a merchant supplier and said that TSMC is ing from 104116 lm/W at 85C and 25C,
solutions that can be delivered to thousands already supplying some customers. The com- respectively. At 2700K those numbers drop
of people. This is another example of how we pany also plans to open an office with busi- to 8191 lm/W.
are continuing to evolve our Xfinity Home ness and technical staff in Shenzhen in the The TME, TMG, and TMH COB LEDs serve
product by creating more innovative home Guangdong province of China to better sup- the ranges 1018W, 2030W, and 4060W,
control solutions for our customers to enjoy. port lighting manufacturers in that region. respectively. TSMC said that the LEDs are
The 11W Ultra iQ lamps target floodlight The new LEDs include the TH3 that is a sin- compatible with the footprints required for
usages and deliver 700 lm at an efficacy of gle-die design set in a standard 3030 plastic use in Zhaga modules. The efficacy is in the
63 lm/W. Comcast customers will be able package. The new chip-on-board (COB) LEDs same ranges as the single-emitter LEDs, and
to control the lamps with a smartphone or include the TME, TMG, and TMH series that the COBs are rated at either 29V or 38V for-
through the Xfinity gateway. are increasingly larger in both package size ward voltage.
MORE: ledsmagazine.com/news/10/6/9 and light-emitting surface (LES) area. MORE: ledsmagazine.com/news/10/6/6
______________
_________________________
funding
programs
USDA and SETi
document UV
LED benefits for
fresh produce
Sensor Electronic Technology Inc. (SETi)
has announced the results of a three-
year research program, conducted
with the US Department of Agriculture
(USDA), that prove ultraviolet (UV)
Zhaga expands certification LED lighting is an effective technique
in extending the shelf life of produce.
program, adds GLA liaison Strawberries in a refrigerator that were
continuously lit with LEDs in the 280
The Zhaga Consortium has authorized three organizations website soon. The organiza- 315-nm UVB wavelength range exhibited
test organizations to issue certifications for tion had previously published Books 2 and no mold or decay after nine days.
solid-state lighting (SSL) products that meet 3. Certification testing for Books 5 and 6 Findings of this exciting program are
Books 4, 7, and 8, thereby formally starting should come soon. expected to have a major impact on the
the certification process for those specifi- The liaison agreement with the GLA could appliance business to extend the shelf
cations. The organization also signed a liai- help accelerate adoption of the modular life and preserve nutritional value of the
son agreement with the Global Lighting Zhaga approach to SSL. The GLA is char- fresh produce, said Remis Gaska, pres-
Association (GLA). tered to promote sustainable energy-effi- ident and CEO of SETi. UV LEDs are an
Zhaga calls its specifications for modular cient lighting and is a top-level organization especially good match for application
light engines Books, and the industry coali- that includes leading national and regional inside refrigerators, according to SETi.
tion continues to expand the applications lighting industry associations in Europe and Because LEDs can be turned on and off
covered by the specifications. Book 4 covers elsewhere. The partnership will entail Zhaga instantly, appliance makers could design
a non-socketable light engine with separate regularly updating the GLA on Zhaga activi- a refrigerator in which the UV lighting is
control gear or driver. The intended appli- ties so the GLA can communicate the bene- turned on only when the door is closed.
cations are high-output fixtures including The energy efficiency of LEDs means
street lights and industrial high-bay lumi- that a refrigerator equipped with such
naires. Already Philips Fortimo HBMt lighting would use little additional energy.
modules designed for street The research project used only 20 mW/m2
light applications fits of the stan- of power. Gaska added, We look forward
dards to more than 5,000 to the prospect of UV LEDs in residential
global lighting manufacturers. refrigerators impacting everyday life and
The liaison agreement carries the implicit reducing waste through spoilage.
message that the GLA is endorsing Zhagas The researchers placed eight tubs of
are listed as certified belief that modular LED light engines can strawberries in a chiller cabinet set to
on the Zhaga website. lower R&D costs for lighting manufacturers 5.4C (41.72F) and humidity between
Book 7 targets applications such as office and provide a broader choice among inter- 9498%. Two tubs were left in the dark.
lighting and defines a non-socketable light changeable products from multiple vendors. In the other six tubs, the team mounted
engine with separate driver. Modules such as For Zhaga, the agreement will provide a con- a single LED in the top cover of each tub
the certified Philips LED Line series (pictured) duit for it to spread its message. The light- testing LEDs over different wave-
would typically find use in ceiling troffers. ing industry operates on a global scale, and lengths and power levels.
Book 8 defines a socketable light engine the specifications being developed by Zhaga Strawberries in the unlit tubs exhib-
with integrated driver for applications such are for global use, said Menno Treffers, sec- ited mold and decay after three to four
as downlights. The term socketable implies a retary-general of the Zhaga Consortium. It days. Strawberries lit with UVC (100
light engine that can be replaced or installed is very important for Zhaga to be able to 280-nm) LEDs were mold free after nine
in a fixture without tools. share the results of its work throughout the days but showed some sign of decay. The
Zhaga announced that Dekra, UL, and international lighting community, and the fruit lit with UVB LEDs was mold and
VDE are authorized to issue test reports liaison with GLA provides a clear route to decay free after nine days.
on the new specifications. Zhaga said the achieve this goal. MORE: ledsmagazine.com/news/10/5/14
full specifications will be published on the MORE: ledsmagazine.com/news/10/6/12
DOE awards $10.1 million in new research awards MSSLC will host annual
As a response to the SSL Manufacturing Eaton Corp., Menomonee Falls, WI, with
R&D funding opportunity announcement a $2.4 million DOE investment, will develop
meeting in September
made in December 2012, the US Department an innovative manufacturing process that The DOE has announced that its
of Energy (DOE) has competitively selected streamlines LED fixture design and removes Municipal Solid-State Street Lighting
five solid-state lighting (SSL) projects to unnecessary materials and parts. Consortium (MSSLC) will hold its
receive the fourth round of funding. The OLEDWorks, LLC, Rochester, NY, with a annual meeting in Phoenix on
two-year projects will focus on reducing $1 million DOE investment, will develop and September 11, 2013, scheduled coinci-
costs while maintaining quality by improv- demonstrate new spray printing equipment dent with the Street and Area Lighting
ing the quality and performance of LEDs that reduces overall manufacturing costs Conference (SALC). The meeting will be
and OLEDs. Total DOE funding for the five in OLEDs and may support cost-competi- open to consortium members, although
projects is $10.1 million, while the five com- tive mass production. the agency will also allow others to reg-
panies will put in a matching $10.1 million Philips Lumileds, San Jose, CA, with a $1.8 ister including government and utility
investment. million DOE investment, will develop an staff that work on street light projects,
This partnership with industry to pro- alternative to the standard flip-chip device lighting designers and consultants, and
duce affordable, efficient lighting will save that grows an LED face-down on the sap- finance and budget professionals such
consumers money and create American phire substrate. as from energy services companies.
jobs, said DOE Secretary Ernest Moniz. Its PPG Industries, Inc., Pittsburgh, PA, with Attendees will hear directly from US
another example of how energy efficiency is a $2.3 million investment, will develop a cities that have already undertaken LED
a win-win proposition for our economy. cost-effective OLED manufacturing pro- street light projects. Presentations will
Cree Inc., Durham, NC, with a $2.3 mil- cess to help commercialize an integrated include information on funding options,
lion DOE investment, will develop a modular substrate that includes the glass founda- especially in todays climate with much
design for LED lights that can link together tion and other necessary layers. of the funding from the American
multiple units to fit larger areas. MORE: ledsmagazine.com/news/10/6/5 Recovery and Reinvestment page 21
____________
__________
Affordable BLUE Pumps
for Remote Phosphor Applications
Available in 1W to 24W Packages
Package
Compatible with
LM80 Data Available ChromaLitTM
Remote Phosphors
KR : +82-31-218-1318 / wallace.lee@lumens.co.kr
US : 714-409-0378 / sales@goecoled.com
www.lumens.co.kr
____________
funding programs
Except as otherwise noted, all marks used are trademarks and/or registered trademarks of Henkel and/or its affiliates in the U.S. and elsewhere.
= registered in the U.S. Patent and Trademark Office. 2013 Henkel Corporation. All rights reserved. 10799 (06/13)
preview | THE LED SHOW
T
he LED Show, scheduled for August uncertainty is what will make the session forefront of the movement to use low- and-
1315, 2013, in Las Vegas, NV, will especially interesting because the partici- mid-power LEDs in general lighting prod-
offer an inside look at the solid-state pants surely have different agendas. ucts. The company offering the Nichia 757
lighting (SSL) industry starting from the Paul Scheidt, product marketing man- LED (Fig. 2) in a plastic package has led
LED component level and covering elements ager at Cree, plans to discuss the compo- the industry in reducing component costs.
of indoor and outdoor lighting systems and nent trends that Cree believes have staying At Strategies in Light earlier this year,
design guidelines. The sessions on the latest power. For instance, Scheidt said that tradi- Strategies Unlimited analyst Ella Shum said
in LED components should be lively as the tional high-power LEDs that operate at low that Nichia drove component prices under
speakers come from companies with signifi- voltage and high current have been the only $2/klm [dollars per kilo lumen a bench-
cantly different viewpoints on where compo- technology proven consistently successful in mark figure tracked by the US Department
nents for SSL are headed. A session on indus- the SSL industry. Scheidt
try regulatory and standards issues will be a said, There is always a
must-see with the ongoing changes in that new technology trend
landscape. There will be plenty more to learn thats considered the
in the sessions, and what is expected to be magic bullet to enable
the busiest exhibit floor yet for the event. mass LED adoption.
A pre-conference workshop, conference When pressed, Scheidt
sessions, and exhibits are the cornerstones of said examples of trends
The LED Show. The workshop will take place include remote phosphor,
on August 13 and will focus on SSL retrofits. AC LEDs, and mid-power
Leading lighting designers will present and a LEDs. Many are used but
panel discussion will include lighting consul- often in limited volume
tants and executives from lighting manufac- relative to mainstream
turers. See the full list on the conference web- high-power LEDs. He
site (theledshow.com/conference.html). The added that multi-emitter, FIG. 1. Cree is focused on what it believes are more reliable
main sessions and exhibits will take place high-voltage, low-current ceramic packages for mid-power-class LEDs.
over two packed days, August 1415. LEDs are an example of
one trend that might have lasting value. of Energy (DOE)] by the end of 2012. In con-
LED component update The mid-power trend is an especially hot trast, the average price for LEDs in 2012 was
Kicking off the conference sessions on one right now; however, will it have staying $3.45/klm, and high-end, high-power LEDs
Wednesday morning, executives from Philips power? Scheidt said, I see the long-term reli- certainly sell for more.
Lumileds, Nichia, and Cree will discuss the ability of those parts being their disadvan- Erik Swenson, manager of LED sales at
latest advancements in LED chips. The ses- tage. Cree has announced mid-power LEDs Nichia, said LED component pricing remains
sion will be compelling for both SSL product recently (Fig. 1) but is using what it believes the largest barrier to broader LED adoption.
developers and lighting specifiers who need is a more reliable ceramic package relative to Nichia, and others with low- and mid-power
to understand the light-source technology in the lower-cost plastic packages used by most LEDs, leverages the scale and manufactur-
finished lamps and fixtures. vendors (ledsmagazine.com/news/10/5/13). ing expertise it has gained in manufacturing
The LED component segment is rap- plastic-packaged LEDs for the TV and display
idly evolving, yet the jury is out as to which Plastic packages backlighting industry that has by far con-
advancements will have the greatest impact Nichia will clearly take issue with that line sumed the most white, phosphor-converted
on the lighting industry. And that area of of thinking. The company has been at the LEDs of any application segment to date.
Swenson said that Nichia has brought that the industry should be dancing with
superior luminous density and quality to the one that brought ya, presumably imply-
plastic packages for general lighting. He ing both the leadership position Nichia has
added that the SSL industry is coming full in global LED sales and the fact that the low-
circle, returning to lower-power LEDs, and power LEDs were the first truly high-volume
market for LED manufacturers.
_________________________________
__________________
preview | THE LED SHOW
Solder and
of the LED die from a production run as pos- excellent job administering the program.
sible to minimize component cost while He said, The DLC model is what every Fluxes for LEDs
meeting performance expectations that are energy-efficiency program around the
most easily satisfied by only selling what he world should strive to emulate. Note that
called the upper bins. The answer may lie Marci Sanders of D&R will also present an
in a move to more sub-assemblies or mod- update on Lighting Facts in a different ses-
ules that combine LEDs across the produc- sion at the show (Fig. 4). Solder
tion run and that deliver performance and Attendees wont solely learn about Paste
efficacy without high cost. US programs, either. For example, Glen
Tubrett, director at CSA Group, will dis-
Standards and regulations cuss both Canadian standards for SSL
Meanwhile, another session that will have and the need for manufacturers to have Flux-Coated
Preforms
broad applicability across both the product- a global outlook on regulatory and stan-
dards issues. In particu-
lar, Tubrett said he will
discuss ongoing work in
Canada to harmonize Flux
standards with the UL
standards in the US. But
he will also discuss IEC
standards that are pro- Thermal
mulgated in Europe and Interface
the trend toward global-
izing the function of cer-
tification bodies.
One set of standards NanoFoil
being driven by the light-
ing industry, the Zhaga
Consortium books for
interchangeable modular
FIG. 4. Marci Sanders of D&R International will address LED light engines, has a
the DOE Lighting Facts program at The LED Show. decidedly global scope. UL
will address the progress Learn more:
developer and lighting-specifier spaces is enti- of Zhaga in its presentation. UL recently http://indium.us/F311
tled SSL standards & certifications. Speakers announced that it has been certified to per-
from CSA, UL, and TUV SUD will participate. form testing to Books 4, 7, and 8 (ledsmaga
______
The topic area is critical because assurance of zine.com/news/10/6/12).
SSL product safety and performance is rooted
in such specifications. Moreover, programs The LED Show exhibits
such as Energy Star are critical in the mass Attendees will clearly have an outstanding
adoption of LED-based lighting. educational opportunity in the conference
One program that is critical to success for at The LED Show. Indeed, weve covered
SSL products is the DesignLights Consor- a small segment of the two-day program.
tium (DLC) Qualified Products List. Utili- Still, the exhibits will prove equally valu-
ties and others use that list almost as an able to attendees. As we went to press, the
approved vendors and products list. exhibitor count was approaching 90 with
Jason Chesley, sales manager for energy representation from every major region
efficiency at certification body TUV, will around the world.
cover the DLC program in detail because The event will also include plenty of net-
he said, DLC is the hottest program out working opportunities for industry profes-
there for rebates on commercial SSL proj- sionals. There will be delegate lunches and www.indium.com
ects. Chesley said that D&R International, coffee breaks in the exhibit area. Moreover, a askus@indium.com
a consultancy that runs multiple lighting networking evening reception will be the hot ASIA CHINA EUROPE USA
industry programs such as the DOE Light- spot in Vegas on Wednesday evening once
2013 Indium Corporation
ing Facts Label program, has done an the sessions end.
__________________________
lighting | ADAPTIVE CONTROLS
T
he rapid adoption of LED light sources many energy-efficiency standards are being you save even more energy by dimming them.
is rooted in energy savings, long life, updated to mandate more sophisticated light- Dimming LEDs also makes them run
and new fixture options that enable ing control strategies, effectively mandating cooler, extending the life of the electronic
them to be used in almost any application. dimming in many applications. components in the driver, as well as the
They are highly efficient; deliver a useful life- A wide range of controls are available phosphor in the LEDs. This will poten-
time averaging 50,000 hours; and offer very from a single switch or dimmer to a central- tially double or triple the useful life of the
good color rendering. LED lamps also emit ized lighting control system to provide LED lamp or module. Research is ongoing
very little infrared (IR) radiation and contain maximum flexibility, as well as measurement to better quantify the relationship of dim-
no mercury. Despite these clear advantages, and reporting tools to help you effectively ming LEDs and lifetime extension.
issues of compatibility between LED lamps, analyze the energy savings being achieved Still, you must choose the fixture, driver,
drivers, and controls continue to cause confu- with the lighting and control installation. and control combination to meet project
sion for specifiers and their customers. If they Sophisticated, configurable sys-
are paired improperly, performance will suffer. tems can allow tuning of spaces
The best strategy for selecting an LED based on actual occupant usage
product is a holistic approach that takes into post-installation, which over
consideration a variety of factors including time can allow lower energy
the application type, required dimming per- densities that surpass design
formance, and control requirements. Mock- goals. Furthermore, easy-to-
up installations and expensive, time-con- install wireless controls facili-
suming testing may be necessary before tate simple retrofits, reducing
customers are confident that the proposed installation and programming
lighting system is the best choice. Many LED costs, and improving return on
component and control manufacturers are investment (ROI).
investing more time and effort into dimming Regardless of the control sys-
testing and research, and can provide com- tem you choose, it is critical to
patibility information to ensure successful work with a manufacturer who FIG. 1. There is a linear relationship for dimming level
LED lamp, driver, and control installation. can guarantee compatibility and and consumed power with LED lighting.
performance with the desired
Looking beyond baseline efficiency LED loads, eliminating many of the common needs. LEDs are making great strides, and
LEDs are energy efficient by design. Simply concerns and issues that are seen with LED LED products now exist for replacing vir-
using LED lamps or fixtures can help a facility installations. Lets discuss why and how to tually any fixture type including general-
meet updated building and energy codes while implement dimming in more detail. purpose lighting, downlights, cove lights,
reducing electricity consumption and cost. and outdoor lighting. The type of control
So why worry about dimming your LEDs? For Maximize savings and system life you choose will depend on the results you
the same reason you control any light source: Dimming LEDs saves energy at a roughly want to achieve. For example, in a lobby or
to maximize energy savings, extend system 1:1 ratio, which matches or even exceeds the atrium, a 20% minimum dimmed light level
life, enhance flexibility, increase productiv- energy reduction of dimming fluorescents. is typically acceptable. But in a conference
ity, and provide a safe, comfortable environ- This means that if you dim LEDs down to room or restaurant, very low levels of light
ment for building occupants. Additionally, 50% of their light output you save nearly 50% dimmed down to 1% are often desirable.
of the associated energy use (Fig. 1). While it It is all too easy to neglect the importance
ETHAN BIERY is the LED engineering leader at is true that LEDs are already very efficient of LED dimming range. While 10% dimming
Lutron Electronics Co., Inc. compared to almost any other light source, may sound appropriate for most applications,
our eyes are sometimes too smart for their them? It is the result of
own good. Due to the dilation of the pupil the physical differences
in the human eye, lower light levels are between LEDs and their
perceived as brighter than expected. For predecessors including
example, a 10% light level appears to be about incandescent and halo-
33%. Even 1% dimming is perceived as a 10% gen lamps.
light level (Fig. 2). Incandescent lamps
The expected dimming range should create light by heating
always be part of the product specification, a tungsten wire to high
but it is not always provided by the manu- temperatures in a low-
facturer. Furthermore, even for a given LED pressure glass envelope,
load, the dimming range may vary depend- causing it to glow white
FIG. 3. LED lamps have integral drivers that limit control
ing on the control used. Designers and spec- hot. Electrically speak-
options.
ifiers need to be aware of the low-end light ing, these are very simple
level that can be achieved with the proposed devices the more volt-
LED load and control combination. age delivered to the source, the hotter it got, constructions, and feature sets. One thing
If all the parts and pieces are not carefullyand the more light it produced. With legacy they have in common is that they do not have
evaluated, the result can be dimmable prod- sources the shape of the voltage waveform the same electrical properties as an incan-
ucts that do not work as claimed. For exam- really didnt matter. AC, DC, phase cut, or descent load, and this difference is essen-
ple, you can end up with lights that never turn nearly any other form would provide the same tially the root cause of compatibility chal-
off completely, or that flicker, pop on, or dropamount of light for the same RMS voltage. lenges between controls and LEDs.
out, leaving the end user with the perception LEDs behave very differently. Light is pro- Different manufacturers drivers priori-
that dimming LEDs does not always work. duced by subatomic processes in specially tize different requirements. Some may opti-
designed semiconductor materials. For a mize for cost, some for size, some for life-
Challenges of dimming given LED device, the amount of light gener- time, and so on. Part of the design of the
It is generally recognized that LEDs are inher- ated is proportional to the amount of current driver determines how well, and how low, it
ently dimmable and controllable, so why are (not voltage) passed through the device. Fur- will dim, and using what controls. This fact
there so many challenges with dimming thermore, the current can flow in only one leads to two important conclusions:
direction through an The design of the driver determines the
LED, meaning they best possible dimming performance that
can only tolerate DC can be achieved.
current. (Note that The compatibility of the driver with the
so-called AC LEDs rely control determines how well the driver will
on tricks such as two achieve this performance.
diodes that are wired In essence, even the best control cannot
such that current make an LED lamp dim beyond its design
flows through some parameters. Both poor driver design and
diodes in one direc- improper pairing with a control can lead to
tion, and other diodes undesired aesthetic performance, includ-
in the other direc- ing flicker, drop-out, dead travel, or acoustic
tion.) Finally, LEDs noise (buzzing).
are inherently low- Additionally, poor driver design and con-
voltage devices, typi- trol pairing can lead to reduced lifetime of
cally requiring a large the control or load. A good driver will guar-
reduction in voltage antee smooth, continuous dimming to very
from the mains wir- low light levels on a wide variety of controls
ing. These functions with no negative impact on lifetime, match-
reducing the volt- ing the dimming performance that people
age, regulating it to expect from incandescent lamps. Few driver
DC, and controlling manufacturers in the industry today can
the current are all reliably make this claim.
handled by a device
called an LED driver. Ensuring expected performance
FIG. 2. The human eye perceives much higher light levels than LED drivers come In order to properly align customer expecta-
the actual output from dimmed sources. in a variety of designs, tions with LED system performance, several
877-710-7272 | www.sapagroup.com/NA
Sapa Extrusions North America NorthAmerica.Sales@sapagroup.com
lighting | ADAPTIVE CONTROLS
_________________
lighting | ADAPTIVE CONTROLS
the lights should be off. This behavior is specified in an IEC stan- 10 - 3 0 0 WAT T M O D E L S
dard, 60929, which covers only very basic functionality. For exam-
ple, there is no assurance provided by the standard that smooth, 480V INPUT MODELS
continuous dimming to low light levels will occur. Mixing 010V CUSTOM DESIGN &
fixtures from different manufacturers or using long wire runs for MODIFICATIONS
the 010V signal can cause noticeable differences in light levels
DIMMING OPTIONS
across multiple fixtures.
While 010V allows the control wires to be run separately from
the power wires, it has an inherent disadvantage when multiple
control strategies are desired. By definition, all fixtures tied to DC INPUT MODELS
the same pair of 010V wires are controlled together and will dim EXTREME
together. This fact means that for spaces with multiple control CONDITIONS &
types, where fixtures must dim to different levels due to differ- TEMPERATURES
ing control inputs (such as daylight sensors, personal zone con-
COMPACT DESIGNS
trols, and occupancy sensors), the room must be broken into mul-
tiple areas of control, each with their own 010V wires. Control of US ENGINEERING
010V loads can become very complex to design and install for all SUPPORT
but the simplest applications. One other disadvantage of 010V is
that any change of functionality or fixture zoning requires rewir- AUTEC.COM
___________
ing of the 010V control links.
Check out
our virtual tour! Call 877.479.3680
or visit www.protolabs.com
Visa/Mastercard Accepted
2013 Proto Labs, Inc
___________________
regulations | EUROPEAN STANDARDS
I
n recent years, a large variety of LED- manufacturer. Less frequently, performance fluorescent lamps and therefore should not
based solid-state lighting (SSL) products standards specify absolute requirements have properties that impair the safety of the
has emerged on the market. LEDs have the product should fulfill. luminaires in which the lamps are installed.
now realized their full potential for every- The safety standard for double-capped
day illumination, rather than being limited LED lamps regulation LED lamps, which are intended to replace
to specialty applications. The ever-increas- Due to an increasing interest in energy double-capped linear fluorescent lamps, is
ing number of LED products particularly savings, LED lamps have become more currently being developed. The primary con-
represents a challenge to test laboratories, and more commonly used as the preferred cern for these lamps is their metallic surface.
whose task it is to check for product safety. alternative to incandescent lamps. Until As metal conducts electricity, the safety dis-
Generally, safety testing is carried out by October 2012, it had therefore been an tance from live parts, termed the creepage
testing products against relevant product
standards. However, when new technolo-
gies such as SSL emerge, no specific prod- The standards for LED lighting products
uct standards exist and so only related
standards can be applied. Fortunately, this can be roughly divided into two groups:
situation has now markedly improved in the
LED field around the globe; we will discuss
safety and performance.
the regulatory landscape in Europe.
The standards for LED lighting products awkward situation in Europe, since there distance and clearances, is relatively large
can be roughly divided into two groups: were no specific EN standards for LED lamps. in order to ensure that any accessible metal
safety and performance. As the terms imply, EN 62560, which now becomes the stan- parts do not become live with mains voltage
the first group is mainly concerned with the dard for self-ballasted, single-capped LED under any circumstances.
safety issues related to products, while the lamps, was only ratified in October 2012. Pre-
latter focuses on the performance of the viously, combinations of other EN standards Safety of luminaires
products. Some overlaps occur in the stan- were applied to check the safety of products. The EN 60598 standard series relates to
dards, because some requirements may be However, the corresponding IEC 62560 stan- the safety of luminaires. This series does
safety oriented but are located in the perfor- dard has been valid since February 2011. not have special requirements for LEDs;
mance standard and vice versa. EN 62560 covers LED lamps that replace instead the common requirements of lumi-
In Europe, the safety of the lighting familiar mains voltage household lamps. As naires have to be fulfilled by SSL luminaires.
product has to be ensured according to the it is only intended for self-ballasted lamps, In addition, LED modules and control gear
Low Voltage Directive 2006/95/EC. In the lamps with external control gear, or driv- must comply with their own standards.
Low Voltage Directive, the application of ers, are not within the scope of the standard. Although this is not currently mentioned in
performance standards is not mandatory, Standards for such lamps are under devel- the EN 60598 standard series, the safety of
because they do not affect the safety of opment. The primary purpose of the stan- photo-biological radiation has to be assessed
the product. Performance standards dard is to ensure that the product is not and according to standard EN 62471. (For more
specify requirements for how to test the will not become unsafe during its lifetime in information on photo-biological safety, see
performance characteristics of products. normal use. This goal also applies to cases ledsmagazine.com/features/9/2/9.)
Most of the tests included in performance where the lamp is damaged. The lamp must EN 62471 deals with safety aspects of
standards verify properties claimed by the not impair safety even when the electronics radiation between 180 and 3000 nm, which
inside the lamp fail. The standard also con- includes ultraviolet (UV), visible, and infra-
PASI ORREVETELAINEN is the project centrates on the fact that the LED lamps will red (IR) radiation. Ordinary LEDs intended
manager at SGS Fimko Ltd, Finland. replace ordinary incandescent and compact for illumination do not radiate harmful UV
LED modules and control gear
Usually, several LEDs are combined in SSL fixtures. The printed
circuit board on which the LEDs are placed is often called an LED
Certified to: ISO/TS
16949, ISO 9001 with module or light engine. The safety standard for LED modules is EN
Design and ISO 14001 62031. LED modules can be self-ballasted, which means they have a
For your next project contact our engineers! driver or control gear integrated on the module. However, it is more
problem solvers. solution providers. 855.585.5050 | www.lauren.com/light common for the control gear, which supplies the LED module with
its correct voltage and current, to be a separate unit. For a sepa-
rate control gear, the standard EN 61347-2-13 applies. The EN 61347
series is intended for control gears and ballasts of various types of
lamps. Parts 2-13 are intended specifically for the control gears of
LED modules.
As LEDs do not need very high voltages to operate, it has become
popular to provide an extra-low voltage (ELV), less than 25V RMS, to
LED modules. Relying on ELV levels to the modules simplifies module
safety assurance. If the voltage of the LED module is low enough, it is
safe to touch the LED module with bare hands. However, this requires
that the LED control gear is classified as safety extra-low voltage (SELV)
or an SELV equivalent. The requirement for SELV is not only a low volt-
age, but the SELV circuit also must be separated from the mains supply
by double or reinforced insulation. Thus, if an LED module claims to be
SELV, it requires that the control gear is very safe as well.
Performance
LED products already have their own performance standards.
Most of these standards are IEC/PAS, which indicates that they are
Publicly Available Standards or pre-standards.
EN 62384 is the standard for LED control gear performance. As
mentioned earlier, most of these requirements relate to the proper-
ties claimed by the manufacturer. However, besides an endurance
test, there are requirements for abnormal conditions that the con-
trol gear has to withstand. During and after these tests, the control
gear should function normally.
The IEC 62707 series is a family of performance standards intended
for individual LEDs. The series is under development and the IEC has
______________
currently published one standard IEC/PAS 62707-1 concerning
the color binning of white LEDs. Two additional parts of this standard
regulations | EUROPEAN STANDARDS
Non-self-ballasted:
IEC 62663-1
Performance IEC/PAS 62722-1 IEC/EN 62384 IEC/PAS 62717 IEC/PAS 62612 IEC/PAS 62707 series
will cover LED binning according to luminous lumen maintenance and include colorimetric Europe should engage with a testing lab
flux and forward voltage. properties and their maintenance during the to have the products tested to the relevant
The performance standards for self- products life. These standards include tests harmonized safety and performance stan-
ballasted LED lamps (IEC/PAS 62612), LED lasting up to 6,000 hours. dards. Moreover, competent test labs will
modules (IEC/PAS 62717), and LED luminaires The European SSL regulatory landscape be able to counsel product manufacturers
(IEC/PAS 62722-2-1) will present a broad range is summarized in the table. Companies that on the ever-shifting landscape of LED-cen-
of requirements from electrical properties to intend to sell their LED-based products in tric regulatory issues.
__________
___________________________________
assembly | COB LEDS
T
he lighting market is evolving rap- consumption, thereby lessening the strain on
idly from traditional lighting sources their energy infrastructure.
to solid-state lighting (SSL) technol- One major global effort is to
ogy. The main drivers for this change are the decrease the energy load posed by
need for greater energy efficiency due to ris- the inefficient lighting systems in
ing energy costs and new legislation, both of use today. Increasing global popula-
which have global implications. With the mar- tion and the resulting rise in demand for
ket drive to mass adoption of SSL technology, lighting can no longer be served by incan-
lighting manufacturers must adapt to faster descent sources that accounted for 79% of
product development cycles that more closely light source sales volume in 2006. Collec-
match developments in LED technology. tively today, lighting energy consumption
Developing fixtures that incorporate chip-on- accounts for around 18% of the total global
board (COB) LED arrays is one avenue toward generated energy and cannot be allowed to
faster development, although that choice continue. Simply switching to readily avail-
also comes with challenges in how to imple- able, more energy-efficient light sources
ment the electrical, thermal, and optical inter- such as CFLs or LEDs can result in a 40% FIG. 1. A chip-on-board (COB) LED
faces with the LED. This article provides back- energy savings that would eliminate 630 packs a dense array of LEDs.
ground on COB technologies, summarizes the million tonnes of CO2 and 1800 million bar-
issues and challenges with COBs, and suggests rels of oil. It would further cut down on the
a unique luminaire assembly and interconnect power-generating footprint, eliminating
approach that simplifies luminaire design. the need for almost six hundred 2-TW/yr
The world is facing a wide range of energy- power plants. Although it is neither feasible
related issues ranging from oft-debated nor realistic to expect this change to hap-
global warming to diminishing fossil fuel pen overnight, phased regula-
supplies. Power generation limitations due tions are in place around the
to increasing demand or resulting from nat- world to ban the incandes-
ural disasters in various regions result in cent bulb. These are progress-
brown-outs or even black-outs that directly ing and driving the changeover to
affect quality of life for residents. These dis- incandescent alternatives primar-
ruptions can extend to national productiv- ily turning to the LED moving forward.
ity due to decreased manufacturing output
at companies located in those regions. Politi- HB LED evolution
cal, economic, geographic, or logistical issues Lets move on to LEDs, the evolution of the
often limit adding power generation capac- technology, and the challenges of SSL devel-
ity to address the increased demand. Given opment. LEDs have gone through a signif- FIG. 2. Companies initially developed
this environment, countries around the icant transition since their inception that custom sockets for each LED from major
world are fully engaged in trying to minimize mimics the evolution of the single semi- manufacturers.
their carbon footprints and decrease energy conductor transistor device morphing into
the integrated circuit we know today. Early manner similar to transistors, an indicator
RON WEBER is the industry market manager LEDs were low-power devices used for indi- LED that cost $300 in the 1960s can now be
for lighting and security at TE Connectivitys cating purposes and are still in wide use purchased for less than $0.05 in a number of
Industrial Business Unit. today across many applications. In a different package styles. As with transistors,
LED technology transitioned from its origi- clearly positioned as broad angle emitters
nal format as a low-power device to a high- their large source size becomes very difficult
power device in the late 1990s/early 2000s. to effectively focus into a small beam angle.
While these earlier devices were considered As a result, COBs are now found in applica-
high power, they were single-die packaged tions requiring large amounts of light spread
emitters with very limited light output and out across a large area as seen in high bay and
limited practical use. street lighting. Still, optics such as reflectors
In an effort to increase light output, com- can also enable the use of COB LEDs in appli-
panies began placing multiple die in a lead- cations including downlights and even reflec-
frame style package to increase light output tor-based retrofit lamps.
and individually placed phosphor dots on FIG. 4. A pair of holders that reference
each die to tune color. Around 2005, a new Connecting packaged LEDs the corners of the LED can work with
LED package was developed that eliminated Over the years, multiple connector companies many different COB LEDs.
the secondary LED package and placed the developed a number of sockets for the high-
die directly on a metal-clad PCB substrate power LEDs that came to market. In fact, the
collectively called chip-on-board or COB idea has spread that an LED is just another to address each would be a challenge to say
(Fig. 1). Rather than individual phosphor device to be connected to. Sockets such as the the least. Aside from the fact that all were
dots on each die, these COBs are character- TE Type LS and Type NL2 (Fig. 2) devices were rectangular, all had two electrical contact
ized by a yellow-orange phosphor pool or dedicated to a particular manufacturers LED pads, and most had circular light emitting
slurry that covers all die and is typically cen-
package and therefore had limited applicabil- surfaces, there were few other dimensional
tered on a white-colored substrate, giving ity beyond the specific targeted LED. similarities. The challenge for connector
these LEDs the nickname fried-egg LEDs The emergence of COB LEDs posed dif- companies was how to address these varied
due to their appearance. ferent challenges to fixture manufacturers: but similar COB LEDs with a minimum of
These COB LEDs have undergone a prolifer- how to provide power to these devices and engineering and tooling expenditure while
ation over the past couple of years as all major
then affix them to heat sinks in the light- providing a future-proof and flexible plat-
LED manufacturers began offering COB prod- ing fixtures. The traditional method was to form based product.
ucts to the market. Unlike the smaller pack- hand-solder the wires to the pads on the sub-
aged LEDs that are considered point source strate (Fig. 3) and then secure these assem- Scalable interconnects
emitters, COBs by their nature are wide area blies with screws to the heat sink a pro- One solution to the interconnect challenge
emitters with up to 204 0.25-mm2 die packed cess that was time consuming and subject is a flexible, scalable, platform-based socket.
into a 12-mm-diameter area as seen in prod- to variability. As with the earlier discrete An analysis of available COBs yielded a crack
ucts offered by Nichia Corporation. In some devices, this presented an ideal opportu- in the shell of these fried egg LEDs. While
nity for socket solutions.
instances, larger die are used in large arrays not exactly identical, there are similarities
as seen in the Bridgelux products that place TE and other connector companies between contact pad locations that, when
64 1-mm2 die in a 35-mm-diameter area. addressed this emergence of initial COB combined with the rectangular nature of
devices the same way earlier discrete LED
With light source areas this large, COBs are the devices and diagonal contact pad place-
packages were addressed: ment, form the basis for the platform solu-
custom sockets. As other tion. As a result, a holder product, refer-
COBs started to enter the enced off the corners of the COB, could yield
market, connector man- a virtually limitless array of use scenarios
ufacturers realized that with the varied COBs available on the mar-
the status quo method ket as well as those to come in the future.
of developing a socket for The substrate differences among COB
each would be prohibi- LEDs from difference manufacturers, how-
tively expensive and time ever, added yet another issue that needs to
consuming, resulting in be tackled by socket/holder suppliers. While
never-ending efforts for- most of the early COBs incorporated alumi-
ever chasing the next new num substrates, further investigation of the
COB to enter the market. commercially available COBs indicated a
With well over 50 dif- number of COBs that are based on ceramic
ferent COB products substrates (typically aluminum nitride).
commercially available While not a significant differentiator, these
FIG. 3. Hand soldering is one option for making the around the world from two substrate variants have physical features
electrical connection to COBs but can be unreliable and multiple manufacturers, that differ enough to require special handling
time consuming. finding a single solution due to their different material properties.
Illuminating Diffuser
in Silicone. Reflector
LED Chip
PCB
Shin-Etsu Silicones propels vital silicone material Highly Reflective Dam Materials:
solutions to provide innovative advantages that KER-2000-DAM
drive advanced LED display and lighting module KER-2010-DAM Heat Sink
performance including: Die Attach Adhesives:
Weatherability / Cycle Time Reduction / Environmental KER-3000 / KER-3100 / KER-3200
Durability / High Clarity / High Refractive Index Over Time SMP-2800 Driver
Driver Potting Compounds:
Shin-Etsus wide spectrum of LED application materials KET-132 / KET-132-H
includes:
Base
High Refractive Index (1.38-1.57) Encapsulants: Shin-Etsu Silicones illuminates pioneering solutions
ASP Series / SCR Series / KER-6xxx Series that drive LED productivity, innovation, and the evolving
KER-2xxx Series demands of the industry.
FIG. 6. The holders must leave a gap on the thinner and brittle FIG. 7. Springs can secure ceramic substrates against the TIM
ceramic substrates. and heat sink.
(TIMs) to optimize the thermal path from stack heights posed by COB applications. secure the COB against the heat sink.
the LED substrate to the heat sink. On the One method is commercially available that When the same system is used with the
other hand, the more durable aluminum utilizes a combination of optional thermal thinner ceramic substrates as shown in Fig.
substrates can use grease or flexible TIMs. springs and housing ledges to accommodate 6, clearance needs to be provided to avoid
Any holder being considered by an SSL both types of COBs. An example using an alu- exerting pressure on the ceramic substrate.
manufacturer needs to be evaluated rela- minum substrate COB is shown in Fig. 5. The The housing design naturally clears the
tive to how it accommodates these varying red circle indicates how the housing is used to thinner ceramic COB as indicated by the red
_________________
assembly | COB LEDS
circle. Since the electrical contact needs. By utilizing a holder designed from
spring is inadequate to provide an the start as a scalable platform, fixture
appreciable normal force for ther- manufacturers gain the flexibility to
mal contact, a secondary thermal utilize a broad range of light source
spring is incorporated and is seen options. From a COB LED manufac-
in Fig. 7. A pair of these springs can turers point of view, the availabil-
exert just the right amount of force ity of a common holder design
on a ceramic device to ensure optimal provides a stable reference
heat transfer when used with most com- for manufacturers design-
mercially available thermal greases. ing a new COB package
since the use of pre-defined
Simplifying manufacturing FIG. 8. By adding arms to the corner contact pad locations ensures the availabil-
While a two-piece socket design affords a sig- holders, companies can supply a ity of an off-the-shelf holder solution when a
nificant level of scalability to accommodate one-piece COB interconnect to SSL new COB is released to the market.
a wide range of COBs, some fixture manu- manufacturers. The global march toward energy effi-
facturers prefer to only handle a single part. ciency continues. LED lighting will play a
Additional levels of scalability can be incorpo- arrays of LEDs can be powered in a similar major role and, as with all new technolo-
rated into a two-piece design by the relatively fashion through pads located on the corners gies, efficiencies are increasing while costs
simple addition of two arms oriented at 90 of the circuit board. are dropping. The need for cost-effective
to each other. These arms essentially create a In conclusion, COB holders, in particu- LED lighting is putting a renewed empha-
scalable, factory-assembled one-piece hous- lar those that reference off the device cor- sis on cost and manufacturability, which is
ing. A customized holder is then available to ners, offer lighting fixture manufacturers a where both COB LEDs and the COB holders
fit a specific manufacturers COB LED (Fig. 8). unique and flexible termination solution for offer customers an ideal cost-effective solu-
A scalable approach to the interconnect their COB LED attachment and interconnect tion that will accelerate LED adoption.
enables a more generic two-piece design or a
customized one-piece design, and either can
be used by the fixture manufacturer with very
little cost difference between the two. Con-
sider the option a stepping-stone approach.
A lighting manufacturer can minimize the
interconnect investment during prototyp-
ing by launching the fixture using a readily
available two-piece holder solution. Once pro-
duction ramp starts, the manufacturers can
switch to a more manufacturing-friendly one-
piece design.
Ideally, having a single holder to accom-
modate all COBs would be the perfect solu-
tion. Given the slight differences in pad loca-
tions between commercially available COB
products and the different plating styles
commonly used, that perfect solution is
still elusive. Nonetheless, with a scalable
holder solution, solderless interconnections
to a broad range of COBs are possible with a
very small number of socket SKUs that can
accommodate a wide range of commercially
available products.
COB corner holders are also quite adapt-
able. An additional benefit to the holders
referencing off the corners of a COB is that
the applicability of these holders can extend
beyond COBs. By using the same corner hold-
ers used to provide power into a COB, large
printed circuit boards containing massive
FEBRUARY 25-27, 2014 : : SANTA CLARA CONVENTION CENTER : : SANTA CLARA, CA, USA
presented by: flagship media sponsors: events: owned & produced by:
automotive | LEDS STANDARDS
T
he majority of drivers feel stressed in
poor visibility conditions, particu-
larly at night when the ability to per-
ceive and judge distance is severely impaired.
Despite much lighter traffic on the roads at
night, around 40% or more of all traffic fatal-
ities occur in many countries, such as the US,
during night-time hours. The strain eases and
safety greatly increases if the road ahead is
well lit. The recent introduction of LED-based
lighting for autos is set to improve driver
safety and comfort at night, as well as dur-
ing the day, and offer additional advantages
in cabin lighting. Moreover, international
standards will play a key role in the move to
solid-state lighting (SSL) in the auto.
The need for drivers to see other vehi-
cles and to be seen by them after dark
emerged naturally as soon as cars first
appeared on roads. Lighting had been pres-
ent on horse-drawn vehicles for a long time
because of the same requirement. Initially,
in the 1880s, cars were fitted with acetylene FIG. 1. The use of LEDs in daytime running lights, such as in this Hella design for the Audi
and oil lamps. Vehicular lighting had begun A8, and combination rear lamps reduces energy requirements during the day by 95%.
a long evolutionary journey.
Early car electrical systems were rather Slow initial progress luminous flux and longer useful lifetime.
unstable and the lamps were subjected to Because the ability to see ahead properly is Xenon lamps that generate light based on
harsh conditions, such as shock and widely fundamental to safe night driving, improv- the principle of gas discharge were first fit-
varying climatic conditions and tempera- ing the performance of headlamp light- ted to motor vehicles in the early 1990s. The
tures. All of these contributed to the some- bulbs has always been seen as essential. xenon lamps represented a major improve-
what slow large-scale implementation of Until the introduction of high-intensity dis- ment over halogen lamps as their color
electric lamps, which started only in the charge (HID) lamps, also known as xenon temperature is closer to daylight, they are
1920s. Other lamps besides headlamps and lamps, the light source used in incandes- brighter, they have a greater range, they bet-
tail lights have been introduced gradually cent headlamps was a tungsten filament ter illuminate the edges of the road, and they
to meet additional needs. They include fog placed in a vacuum or inert-gas atmo- last at least twice as long as prior lamps. The
lamps and various kinds of signalling lamps sphere inside a bulb or a sealed unit. The main drawback to xenon is glare, which can
such as indicators and brake, emergency, main drawback of tungsten bulbs is that be reduced by various automatic devices. In
parking, and reverse lights. their luminous flux (intensity) drops signif- spite of their qualities, they are not as widely
icantly after some 1,000 hours. The tung- adopted as halogen lamps.
MORAND FACHOT is the communications sten bulbs were further improved with the The introduction of LED-based automotive
officer for the International Electrotechnical introduction of halogen gas in the bulbs in lighting is a relatively recent development.
Commission (IEC). the early 1960s. Halogen bulbs had a higher The first LED rear lights and headlamps
Differing requirements or light signaling device, or to be elements of a lifetime and use less energy than fila-
The basic function and interchangeability module or light engine. The auto industry has ment or discharge lamps. LEDs are up to
of filament and discharge lamps for road developed replaceable LED modular sources, 40% more energy efficient than the for-
vehicles differ from those of LED light usually intended for sale to the general public mer sources. Since less energy for lighting
sources. The former types must comply as a replacement part. translates into lower fuel consumption,
with the IEC 60809 International Standard this is a significant feature at a time when
that defines the dimensional, electrical, Unparalleled flexibility and benefits tighter consumption and emission rules
and luminous requirements of lamps for LED light sources can replace all other types are introduced in all countries even though
road vehicles. In particular, this standard of automotive lamps. They are available for road vehicles are required now to use DRLs.
defines the markings, bulbs, dimensions, headlamps (high and low beam), brake lights, r%FTJHOGMFYJCJMJUZ"WFSZJNQPSUBOUCFO-
colors, caps, and bases. rear combination lamps, center high-mount efit of LED lighting solutions for car man-
LED light sources, which are based on stop lamps, daytime running lamps (DRLs), VGBDUVSFSTJTUIFEFTJHOGMFYJCJMJUZUIFZ
modules (LED components used by the turn signals, interior reading lights (map offer. Car design bureaus have much
industry), are not covered by IEC 60809 but lights), dome lights, accent lights, fog lamps, greater freedom to come up with innova-
by other IEC standards specific to LED mod- and position and marker lamps. Moreover, tive designs using lighting to accentuate
ules. However, another International Stan- LEDs are being used for ambient lighting and or attenuate certain shapes and give cars
dard, IEC 60810, which sets out the per- in dashboard and instrument lighting. a common brand signature. LEDs were
formance requirements of lamps for road In addition to enhanced driving safety GJSTUGJUUFEUPWFIJDMFTGSPNUIFFYDMVTJWF
vehicles, applies to the three types of lamps. and comfort, LED light sources offer many segment of the market, but they are found
LED light sources must meet conditions other benefits: now in all classes of cars.
that do not necessarily apply to filament and r-JHIUJOHGMFYJCJMJUZ-JHIUJOHSFRVJSFNFOUT
discharge lamps, in regard to UV radiation, and limitations vary greatly according to Potential not exhausted
color maintenance, and electromagnetic traffic conditions. LED lighting solutions LEDs for automotive or other applications
compatibility. As LED light sources have a allow the optimal use of environmental are constantly evolving. Their potential in
longer rated lifetime than filament or dis- and traffic-related dynamically control- UIF BVUPNPUJWF TFDUPS JT TFU UP FYQBOE BT
charge lamps, their lumen maintenance is lable light distribution patterns such as LED modules improve and with the intro-
assessed differently. dynamic bending of light or adaptive front duction of new technologies such as OLEDs
Another issue that manufacturers have had lighting systems (AFSs), already used for (organic LEDs), which produce a comfort-
to deal with is thermal management, and LED other types of automotive lamps. Such able and homogenous light.
modules and light sources often come with adaptive lighting is particularly impor- Night driving does not depend only on
integrated heat sinks. Unlike their filament tant to avoid blinding other drivers when good vehicle lighting but also on superior
and discharge counterparts, LED light crossing or following other vehicles, espe- road signage and lighting. LEDs are also
sources are mainly of the non-replaceable DJBMMZJODVSWFT
PSUPCFUUFSTFFGJYFEPS increasingly showing the way in this very
type and are usually intended as components moving obstacles on road sides. LED light- significant area. More benefits of LED light-
for integration into the luminaire or lighting ing sources are also dimmable. ing have yet to been discovered and it can be
device by manufacturers. They are designed r%VSBCJMJUZBOEFGGJDJFODZ-&%TGPSBVUP- safely assumed that they will have a bright
and meant to be indivisible parts of a lighting motive lighting have a much longer rated future in the road traffic environment.
WHY ATTEND
FEATURED SPEAKERS
manufacturing | PROCESS CONTROL
L
ED manufacturing is undergoing a Klarity LED - Automated defect analysis tool
tremendous transformation. The evo-
lution to high-brightness LEDs, larger
wafer size, and new complex architectures Substrate Epitaxy FEOL BEOL Yield and binning
make LED manufacturing more challenging (Brightness, Wavelength,
than ever before. Even though these trends FWHM, V_Breakdown,
V_forward, I_Leakage)
greatly benefit the advancement of the solid-
state lighting (SSL) industry in terms of LED
efficiency and performance, they can poten-
tially impact yield in a negative way. In order
for LED manufacturers to stay competitive
in this dynamic environment, they need to
Candela 8620 ICOS WI-2280 ICOS WI-2280
have a comprehensive in-line process con-
trol strategy to improve the yield and drive Many steps in between
down the cost of LEDs and SSL end products.
Currently, most LED manufacturers rely Epi defect to yield and binning correlation?
on inspection tools to analyze wafers and
document defects of interest (DOI). Defect FIG. 1. In-line monitoring should be applied across the multiple stages of the LED
density is typically utilized as the gauge for manufacturing process.
statistical process control (SPC). However,
the drawback of this approach is the fact We know that in-line monitoring is crit- Fig. 1. In general, the manufacturing process
that there can potentially be a lot of nui- ical in determining how defects affect the consists of four essential stages namely
sance defects that do not cause yield loss. yield and a proper strategy would have substrate, epitaxy, FEOL (front end of line),
In looking at a defective wafer through tremendous return on investment (ROI). and BEOL (back end of line) before going
an inspection tool, how do you determine Further to the point, the current method to final assembly.
which defects are killer defects that impact of using total defect density is impracti- First of all, the main substrate utilized in
the yield or electrical performance, and cal. Hence, we will introduce a systematic the production of LEDs is sapphire, gallium
which defects are simply a nuisance? Manu- methodology to identify yield-impacting arsenide, or silicon carbide. There are also
facturers need to detect killer defects at the defects and mapping the relationship of other initiatives for alternative substrates
earliest possible time in terms of the repet- defects to yield. such as gallium nitride and silicon. With any
itive epitaxial-growth wafer-production substrate, a crystalline boule is produced in
runs in an MOCVD (metal organic chem- LED manufacturing process a similar fashion as the semiconductor pro-
ical vapor deposition) reactor. Ideally, the Before we jump into the details of the cess in the integrated circuit (IC) industry.
manufacturer will optimize the MOCVD advanced process control technique, we The boule is normally sliced into very thin
process over time to reduce killer defects, want to take a step back and go over the LED wafers with a diamond saw, and after slic-
whereas a line without such monitoring can manufacturing process flow. Understanding ing, they are polished via a rigorous process
lead to whats often called an excursion this process flow can help us to understand before being shipped to the LED manufac-
or the shutdown and revamping of part of where crucial inspection points occur, and turer for further processing.
the manufacturing process. how process control can help improve time In the next stage known as epitaxy, addi-
to corrective actions, which translates to tional layers of semiconductor crystal are
STEVEN CHEN is a process control solutions higher ROI. A simplified version of the LED grown on the surface of the wafer. MOCVD is
technologist at KLA-Tencor Corporation. manufacturing process flow is depicted in a popular method for the epitaxial growth of
p and n layers with Wafer ID Yield (%) production run, bad Green die indicates a good die, so:
quantum wells in die bear the same cost GCD - Good clean die
Wafer 1 60
between. The typi- as good die because
cal thickness of the Wafer 2 70 bad d ie a lso have GDD - Good dirty die
p and n layers com- Wafer 3 80 to be processed all TCD - Total clean die (Good + Bad)
bined is around Wafer 4 90 the way through the TDD - Total dirty die (Good + Bad)
a few microns. It Wafer 5 60 LED manufacturing
is important to Wafer 6 70 steps. Therefore, early
have an inspec- defect detection and FIG. 2. Monitoring tools can identify defects and then
Wafer 7 80
tion point before remediation when a correlate them to yield.
MOCVD because Wafer 8 90 line is started is the key
poor quality of Wafer 9 75 to reducing manufacturing cost over time. Back-end processes
the incoming sub- Wafer 10 80 As LED structures become more complex, After the wafers go through FEOL, they go
strate can poten- Wafer 11 90 the ability to bin defects and understand the on to BEOL where die singulation, testing,
tially be the culprit location of defects becomes increasingly and sorting take place before final assem-
Wafer 12 80
of future electri- important and requires inspection through bly. Pre-dicing and post-dicing singulation
cal probe test fail- Wafer 13 60 the FEOL stages. The same defect on differ- inspection is essential to enable process con-
ures downstream Wafer 14 70 ent LED structures will have different yield trol and improve the yield. Post-singulation
such as fail- Wafer 15 90 or electrical performance impact. In addi- should look for defects to ensure that the sin-
ing forward volt- Wafer 16 80 tion, defects with certain attributes are gulation tooling does not damage the wafers.
age and reverse Wafer 17 80 more critical and yield relevant than others For example, scratches on the die and the
leakage current at certain locations. presence of foreign matter can potentially
Wafer 18 70
specifications. The inspection equipments defect detec- cause the die to crack during testing. The
F u r t he r mor e , Wafer 19 80 tion sensitivity and accurate classification WI-2280 is also utilized for BEOL inspection
defects from sub- Wafer 20 70 capabilities are needed to ensure that man- to look for yield-relevant defects.
strate and epitax- Average 76.25 ufacturers have a good set of data for anal- After die singulation, die attachment
ial processes can ysis and process control. Wafer inspectors and wire bonding take place before encap-
TABLE 1. Yield data
impact device per- such as the WI-2280 are capable of inspect- sulation and final assembly. Packaged LED
for a theoretical set
for ma nce, rel i- ing all patterned wafers at various process inspections to examine assembly defects
of wafers.
ability, and yield. steps such as lithography, etch, and metal- such as missing die, defective wire bonding,
Equipment such as the Candela 8620 is capa- lization. In addition, the WI-2280 has a high and misplacements also happen at this stage
ble of performing unpatterned wafer inspec- defect capture rate, a unique defect classi- before taping and shipping them out.
tion at the substrate and epitaxy stages. It fication capability, and an advanced recipe Finally, it is crucial to tie these inspections
is crucial to catch defects at these early tuning engine that can be tightly integrated together and perform process control. The
stages to allow faster time-to-root-cause with advanced analysis software for process inspection equipments defect detection
determination and improved MOCVD reac- control and further evaluation. sensitivity and classification capabilities
tor uptime and yield. In addition, the wafer
inspection system is not only able to catch
defects precisely, but it also classifies the
defects accurately. This information is
important for in-line process monitoring
and SPC control.
Front-end processes
The next steps after epitaxial growth are
the FEOL steps. FEOL in the LED pro-
cess is similar to the semiconductor pro-
cess but with fewer steps, and involves the
wafers going through cleaning, lithogra-
phy, etch, metallization, deposition, and
anneal before going to BEOL. Patterning for
enhancing light extraction also happens in
the FEOL steps.
It is important to realize that, for any
single set of wafers that goes through a FIG. 3. A kill ratio study can be performed on multiple types of defects.
Experience the latest technologies with Dont forget to attend the 2013 Networking Reception on
nearly 100 exhibiting companies, displaying innovative, Wednesday August 14. With complimentary appetizers
state-of-the-art lighting technology, and services. This is a and drinks provided this important networking event will
great opportunity to discover whats new in the fast and attract all attendees and provide an excellent opportunity
to engage face-to-face with potential customers.
ever changing LED Lighting sector.
EXHIBITORS INCLUDE:
888 MANUFACTURING CORP EAGLERISE E&E USA, INC JFH Group International Product Safety Consulting, Inc.
AI TECHNOLOGY EBG Tech JIANGSU WEIHAO ProMEMS Technologies Corp.
American Standard Circuits, Inc. ERG LIGHTING ELECTRONIC TECH. CO., LTD Sansitech USA
Autec Power Systems EUCONTROLS CORP Keri LED Lighting
SENTRY ELECTRIC
BARTCO LIGHTING EYE Lighting KONICA MINOLTA SENSING
SEOUL SEMICONDUCTOR
BERGQUIST COMPANY Fusion Optix Inc AMERICAS
SHENZHEN Cidly
BITRO GROUP, INC G-LED USA INC. Lakeview Industries
Optoelectronic Technology
CA Supply Co Green Lighting LED LED Folio Corp
Co.,Ltd
Carson Technology Company, G-S PLASTIC OPTICS LIGHT LABORATORY, INC.
SinkPAD Corporation
Ltd HASTEST SOLUTIONS INC Lumenoptix
Standard Rubber Products Co.
CENTERLIGHT Inc Hero Sail Lighting Inc. LUMINIT
LUXUL Technology, Inc. SUNLED Corp
Chroma Systems Solutions, Inc. Honeywell Lighting Solutions
Moreland Lighting, LLC Taica North America
CITEL INC IGlo, LLC
MORSTAR ELECTRIC Corporation
CLEANLIFE LED INCLUX Co., LTD
MOSO USA, INC. Tempo Industries
COLLECTION DEVELOPMENT, INNOCE
INC. Intermark USA, Inc. National Bright Lighting TUV Rheinland of North
Cree, Inc. INTERTEK OCEAN OPTICS America, Inc.
CSA GROUP io Lighting OHYAMA LIGHTS TUV SUD America Inc
DJ Solar Co., Ltd IOTA ENGINEERING POWER 277 VaOpto
DK THERMAL Limited Itswell Co., Ltd Powerbox USA VIRIBRIGHT LIGHTING, INC.
DLU Lighting USA JAPAN MAGNETS INC PRISM LIGHTING WAVIEN
WANT TO JOIN US? BOOK YOUR EXHIBIT SPACE BY CONTACTING A MEMBER OF OUR SALES TEAM TODAY:
GLOBAL USA EAST COAST: EUROPE:
Tim Carli Mary Donnelly Virginia Willis
+1 650 946 3163 T: +1 603 891 9118 +44 1992 656 663
tcarli@pennwell.com E: maryd@pennwell.com virginiaw@pennwell.com
REGISTER AT www.theledshow.com
($25 charge if you register onsite)
manufacturing | PROCESS CONTROL
need to be matched with yield management a dder defect s DOI Low-impacting DOI bin Yield-impacting DOI bin
software that ties all the data together. (such as particles),
Defect_Type1 Defect attribute 3 Defect attribute >3
The software needs to be capable of while a dirty die
taking the inspected data from various contains detected Defect_Type2 Defect attribute 5 Defect attribute >5
inspection points and providing analysis adder defects. The Defect_Type3 Defect attribute 7 Defect attribute >7
and monitoring. In the next section, an square boxes rep- Defect_Type4 Defect attribute 4 Defect attribute >4
example of in-line monitoring is introduced resent die and the
to demonstrate how to tie the data together dots represent TABLE 2. Yield-impacting defect of interest definition.
to provide meaningful analysis and results. defects. Green
boxes indicate good die while white boxes formulas. In an actual production sce-
Methodology overview indicate bad die. Therefore, good clean die nario, manufacturers would perform such
As mentioned before, it is crucial to distin- means good die without defects. Good dirty an analysis on different types of defects.
guish yield-impacting defects from nuisance die means good die that have defects. Fur- By binning defect attributes such as defect
because not all defects impact the final yield. thermore, we also have total clean die and size and defect location with the kill ratio
Thus, we need to understand the relation- total dirty die. results, one will finally be able to observe
ship between epitaxial defects and their The equations below are the yield and kill the correlation to yield. In other words,
impact on yield, as well as to create a system- ratio formulas. defects with higher kill ratio have more
atic approach in separating yield-impacting Yield formula: YDirty Die = YClean Die * YParticles
negative impact on the yield.
DOI from nuisance. In order to establish a After the data is gathered, we need to
proper process control loop, advanced defect (GDD ) (GCD ) obtain accurate bin sort data, a list of
= * (1-KR )
(TDD ) (TCD )
equipment such as that depicted in Fig. 1 is wafers, yield information, and defect types
needed. Defect information inspected from Kill ratio formula: (GDD * TCD ) from the inspection tools. Then, we use a
KR = 1-
substrate, epitaxy, FEOL, and BEOL can (GCD * TDD ) yield management software tool, such as
feed into an automated defect analysis tool. Potential die loss: dirty die * kill ratio
KLA-Tencors Klarity LED, to perform the
In the case presented here, we are going to analysis. Here, we need to ensure that the
focus on whether the epitaxial defect density Generally, yield is simply the number of defect map accurately aligns with the bin
correlates to yield. good die divided by the total number of die. sort map. It is crucial to have an accurate
One approach to separate yield-impacting In this case, however, we are focused on the wafer alignment because it is the basis
DOI from nuisance is to use what is called yield impact strictly of the die that have at of the kill ratio analysis. Using this kill
kill ratio analysis. Kill ratio represents a pro- least one instance of the defect of inter- ratio information, we can derive the yield-
portion of defects estimated to cause die est, and that leads to the aforementioned impacting DOI definition. Once we have
failure. The kill ratio is
derived from data gath- Wafer ID Low-impact defects Yield-impacting defects Total defects Yield (%) Total defects
ered over prior produc- Number of
Wafer1 60 1300 1360 60 UCL sample failed Yield (%)
tion runs and is used Wafer2 710 1000 1710 70 1600 2 76.25 + 3.75
to find the amount of Wafer3 1050 480 1530 80 1400 3 76.25 + 3.75
1200 8 76.25 - 0.62
defects on a current Wafer4 930 60 990 90
1000 15 76.25 - 1.25
inspection that will Wafer5 60 1140 1200 60 800 19 76.25 - 0.20
cause die failure at the Wafer6 120 950 1070 70 600 19 76.25 - 0.20
end of the process. Wafer7 550 450 1000 80 400 20 76.25 - 0.00
Wafer8 1100 30 1130 90 200 20 76.25 - 0.00
In order to under- Example: UCL = 1400
stand how kill ratios Wafer9 750 560 1310 75
Yield-impacting defects
Wafer10 730 405 1135 80
help in separating yield- Number of
Wafer11 1110 25 1135 90 UCL sample failed Yield (%)
impacting DOI from 1000 3 76.25 - 16.25
Wafer12 620 360 980 80
nuisance, we need to 900 5 76.25 - 12.25
Wafer13 70 1080 1150 60
understand the kill ratio 800 6 76.25 - 11.25
Wafer14 140 890 1030 70 700 7 76.25 - 10.54
model terminology. Fig. Wafer15 1650 75 1725 90 600 8 76.25 - 10.00
2 illustrates this con- Wafer16 1000 275 1275 80 500 9 76.25 - 9.03
cept. Bin data repre- Wafer17 1100 230 1330 80 400 12 76.25 - 5.83
sents good or bad die 300 13 76.25 - 5.10
Wafer18 170 760 930 70
200 15 76.25 - 3.92
identified by bin code. Wafer19 400 140 540 80 100 16 76.25 - 3.44
In addition, the defect Wafer20 700 580 1280 70 Example: UCL = 1000
data identifies clean or
dirty die. A clean die FIG. 4. Tables define yield-impacting defects compared to total defects and the examples of setting
contains no detected control limits.
Design Keynote:
LUCA NICHETTO
Luca Nichetto Design Studio, Stockholm
and Nichetto & Partners, Venice
THURSDAY SEPTEMBER 26, 4:00PM-5:00PM
EXPOSITION & CONFERENCE
IIDEXCANADA.COM #IIDEX13
______________________________
1-800-888-0698
______
___________________________
ZZZVWUDWHJLHVXFRP
_____________________
64"t&6301&t+"1"/
design forum | COLOR MIXING
I
n many solid-state lighting (SSL) appli- VIN
cations, such as architectural, area, and TPS92660
downlighting, color accuracy is very EN/UVLO VIN
VCC
important. Moreover, an increasing num-
ber of products support dynamic color tun- GATE LED1+
ing to set the white point or CCT and/ RON
or to enable dynamic full-color products. LED1+
VO SW
LEDs are ideal light sources for achieving
a precise color. The color of LED lighting GND BOOT VCC
can be changed by mixing different colors
REF
of LEDs, such as red, blue, green, yellow, CS
and white. When mixing LED colors, one or SVDD
COMP
I2 C
more strings of LEDs needs to be dimmed interface SCL
GND
to realize the desired color mix. There are SDA
different methods for achieving LED dim- SADJ LNG
Dimming
ming, so lets consider various dimming signal
LADJ LNCS
techniques used in LED color mixing.
A single LED die can only emit mono-
chromatic light. To generate more colors,
three primary color LEDs (red, green, and FIG. 1. A two-string dimmable LED driver uses a buck converter for one string and a
blue RGB) can be used together for color linear regulator for the second string.
mixing. Seven basic colors (red, green, blue,
yellow, violet, aqua, and white) can be pro- monly used method is to include a red LED Analog dimming options
duced just by switching red, green, and blue string and vary the brightness relative to You implement analog dimming by adjusting
LED channels. To produce more than seven the white string to achieve the desired CCT. the constant current level through the LED
colors, each LED channel must be able to Basically, there are two ways to achieve string. Analog dimming can be achieved by
change in brightness. Dimming an LED LED dimming: analog or linear cur- adjusting the LED current reference voltage
channel is achieved by adjusting the cur- rent control and pulse-width modulation inside the IC, or by adjusting the LED cur-
rent through each LED string. Many colors (PWM). Both dimming methods change the rent sense voltage outside the IC. First, lets
can be produced by mixing three dimmable LEDs brightness by controlling the aver- discuss dimming by changing the LED cur-
strings of RGB LEDs. To change the color age current through the LED string. Both rent reference voltage.
temperature of white LED light, a com- can be implemented in either a switch- For most LED drivers, including switch-
mode or linear LED driver. Fig. 1 shows a ing regulators and linear regulators, the
DAVID ZHANG is a systems applications two-string LED driver containing one buck LED current is determined by the follow-
engineer for TIs LED power group where he switcher and one linear regulator, based ing equation:
is responsible for LED lighting IC systems on the TPS92660. Both LED strings can be
applications. David received his MSEE from dimmed with either analog or PWM tech- ILED = VREF
the University of Texas at Dallas, Richardson, niques. There are advantages and disad- RSNS
Texas and his MS in physics from Marquette vantages to each. In most applications, the Where V REF is the internal IC LED current
University, Milwaukee, Wisconsin. David can dimming method is chosen based on the reference voltage and R SNS is the current
be reached at ti_davidzhang@list.ti.com. color mixing performance requirement. sense resistance.
PWM dimming
Pulse-width modulation dimming actually
4
turns the LEDs on and off at a fixed duty
cycle and frequency. Assuming the switch-
ing or multiplexing is sufficiently fast typ- Ch1 2.0V BW M 10.0 s 125 MS/s 8.0 ns/pt
Ch4 500 mA 1 BW A Ch1 2.32V
ically 200 Hz or greater the human eye
perceives the LEDs to be on continuously. FIG. 3. The PWM signal controls the LED current shown in the bottom waveform.
VIN
TPS92641
VIN
HG
RON
SW
UDIM
VOUT
BOOT
VCC
MOBILE APP
VREF
COMP
CS
EVENT GUIDE
GND
Download the LEDs News & Event
Dimming
Guide App and get the latest
signal SDIM SDRV LEDs and lighting news from LEDs
Magazine at your fingertips. Gain
access to insightful interviews and
FIG. 4. Shunt FET PWM dimming is implemented with a FET in parallel with the LED string. intelligence related to LEDs and
lighting, market trends, industry
innovations and innovators, and
controllers are not available. It can also be The switching regulators inductor cur-
real world applications. A must
used to implement the thermal fold back rent stays continuous during shunt FET
have for Strategies in Light and
function where the LED current is reduced PWM dimming. There is no delay caused by
The LED Show attendees.
by PWM dimming when the temperature of inductor current ramping up or down. With
the LED board rises above a set point. a strong MOSFET driver, the shunt FET can
be turned on and off at very high speeds. Scan this code to download
Shunt FET PWM dimming Consequently, the PWM-dimmed LED cur-
Shunt FET (field effect transistor) PWM dim- rent has very sharp rising and falling edges.
the LEDs News & Events
ming often is used for very high-frequency The shunt FET PWM dimming is ideal for Guide App
high-frequency PWM dim-
ming applications.
There is a disadvantage to Dimming is critical to
using analog dimming in color achieving the desired color
and brightness in LED color-
mixing applications. The LED mixing applications. There
are many approaches to dim-
color temperature can change ming LEDs. The two main
categories are analog dim-
with the LED current. ming and PWM dimming.
Analog dimming usually can
LED PWM dimming. Fig. 4 shows a buck reg- be achieved using a relatively simpler cir-
ulator-based shunt FET PWM dimming cir- cuit. Analog dimming is generally lower in
cuit. An external shunt FET is placed in par- cost and good for a system where a micro-
allel with the LED string to quickly bypass controller is not available. However, it may
(short) the converters output current. The not be appropriate for applications that
LED string is shut off when the shunt FET require a constant color temperature. PWM
is on and is turned on when the shunt FET dimming, alternatively, can achieve very
is off. So the LED string is effectively PWM accurate color temperature by reducing the
dimmed by this shunt FET. Some LED driver color change associated with the LED cur-
ICs integrate a MOSFET driver for shunt FET rent level. PWM dimming usually requires
PWM dimming and eliminate the need for an input digital signal generated by a micro-
an external MOSFET driver. controller and it increases system cost.
F
luorescent tubes have dominated com- lighting service contracts, or LED rental cen-
mercial illumination in American ceil- ter opportunities. This way you dont fully because of dramatically falling prices.
ings for more than 50 years more pay for the technology and arent chasing the But the cost of waiting, in terms of energy
than 2.3 billion tubes are installed, accord- seller if failure occurs. and maintenance, is most likely higher
ing to the US Department of Energy (DOE). Lets turn to technology, and the worry than the price drop, particularly for 24/7
That huge potential retrofit market has that a typical LED tube doesnt give off as illumination areas. At the least, consider a
drawn the interest of many in the solid-state much light as its fluorescent counterparts. rolling retrofit where you replace fluores-
lighting (SSL) space and resulted in a lot of Fluorescent tubes may have more lumens, cent tubes and ballasts as they fail with
myths related to LED tube technology. Lets but 35% percent of the output new LED tube technology.
bust some of those myths, considering that is often wasted going up into There are other cost-related
LED tubes save 50% or more energy over flu- the fixture. Make sure to look issues that are top of mind
orescent tubes. at fixture output side-by-side for some specifiers. Those
To date, the hurdles for adoption of LED in foot-candles after a sample who replaced T12 fluorescent
tube technology fall into three categories: LED tube retrofit. tubes with the better T8 tubes
trust, technology, and cost. Lets explore Others worry that an LED and dont want to upgrade
them, in that order. tube does not have the same again should still calculate
Many believe that the LED tube industry color consistency as a fluo- ROI, especially for 24/7 areas.
has not matured to a trustworthy level, but rescent tube. Yet the thermal Payback is three to five years,
manufacturers have improved thermal man- management of many LED and some worry about war-
agement, and installations now range from tubes has improved to protect ranties in that same range;
Fortune 100 companies to leading health the phosphor coating that dictates color however, as we mentioned, longer warran-
care institutions to leading higher-educa- temperature. Still others question the qual- ties are becoming commonplace.
tion institutions. Organizations such as the ity assurance for LED tubes. The answer is American-made products are more
DesignLights Consortium have qualified to look for LED tube manufacturers that are expensive than imports. Property owners
LED tubes, and warranties have increased ISO 9001:2008 certified. and managers should not focus on the race
to as long as 10 years on some LED tubes. Then there are those who say LED tubes to the bottom of pricing but instead consider
Meanwhile, some worry that imported with external drivers are more difficult the race to the top of performance. All tubes
LED tubes lack UL or CE marks or other to install than internal driver LED tubes. are not created equal, so look at the equip-
trusted output testing. Simply ask for source Not so: Installers need to open the cover to ment and operating cost of a total fixture
documentation and third-party testing data, the fluorescent ballast in order to install versus a tube.
and look into LED tubes that are made either type of driver system, so the time is It cant be stressed enough that specifi-
domestically or that meet the International roughly identical. ers should find a qualified LED manufac-
Class A-10 LED Tube Standards. Finally, some contend that the diodes get turer and start changing out old fluores-
And then there are those concerned that so hot that they burn out the LED tubes. To cent tube technology in 24/7 areas as soon
new LED manufacturers wont be around to combat this, seek out LED tubes with deep- as possible. Switch to LEDs as fluorescent
support the warranty. An easy way to protect fin, aircraft-grade thermal management and tubes fail and make a three-year plan to
your business is to look for performance- external drivers. purge your outdated glass and gas tubes
based programs such as savings shares, Now lets turn to cost where some argue for toxic-free SSL.
range of activities.
1.
1 high-level
hi h l l speakers 6. free presentation
2. market update
7. over 80 exhibitors
3. Two parallel conference tracks 8.
4. The SSL Investor Forum
9. centrally located
5. Workshops industry experts
10.gala reception
Discover more at
ul.com/lighting