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Light engines Modular SSL approach P.49 Color science Optimizing color rendering P.57 Manufacturing Large LED substrates P.63 LEDsmagazine.com FEBRUARY 2013 TECHNOLOGY AND APPLICATIONS OF LIGHT EMITTING DIODES LED LAMPS Lighting manufacturers take myriad approaches P.33 Contents | Zoom in | Zoom out Search Issue | Next Page For navigation instructions please click here Contents | Zoom in | Zoom out Search Issue | Next Page For navigation instructions please click here

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LEDs Magazine February 2013

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Page 1: LED_Feb_2013

Light enginesModular SSL

approach P.49

Color scienceOptimizing color

rendering P.57

ManufacturingLarge LED

substrates P.63

LEDsmagazine.com

FEBRUARY 2013

TECHNOLOGY AND APPLICATIONS OF LIGHT EMITTING DIODES

LED LAMPSLighting manufacturers take myriad approaches P.33

Contents | Zoom in | Zoom out Search Issue | Next PageFor navigation instructions please click here

Contents | Zoom in | Zoom out Search Issue | Next PageFor navigation instructions please click here

Page 4: LED_Feb_2013

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Page 5: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 3

2013features

33 RETROFIT LAMPS Maury Wright

Varying approaches to LED retrofi t lamps show no limit

40 LUMINAIRE DESIGN Tim Whitaker

MHA Lighting takes unique approach to LED fi xture

design with Rods with Holes technology

45 STANDARDS Jianzhong Jiao, Osram Opto Semiconductors

ANSI works to standardize LED datasheet for white LEDs

49 FOCUS ON Skyler Frink & Maury Wright

SSL modules

57 COLOR SCIENCE George Kelly, Avnet

Understand color science to maximize success with

LEDs – part 4

63 MANUFACTURING Marcus Weddle, ARC Energy

Manufacturing LEDs on large diameter substrates:

What’s the holdup?

69 FINANCING Darren Riva, EEF

Energy Effi ciency Financing scheme lights up the path

to green savings

72 DESIGN FORUM Fred Sawyer & Mladen Ivankovic, Infi neon

Fixed-frequency and quasi-resonant fl yback controllers

drive large LED strings

76 LAST WORD Menno Treff ers, Zhaga Consortium

Zhaga helps SSL luminaire makers reduce costs and

supply-chain risks

Cover Story

While incandescent lamps maintained

the same basic look over more than a

century, SSL retrofi t lamp manufacturers

have adopted vastly different

architectures in an attempt to get the

LED point light sources to deliver an

omnidirectional beam (see page 33).

february

columns/departments

4 COMMENTARY Maury Wright

Complex color science underlies good SSL products

9 NEWS+ANALYSIS

Lynk Labs LED light engine dims to warm

Toshiba announces GaN-on-Si LED production start

Konica Minolta buys Instrument Systems

Philips Lumileds announces workhorse Luxeon T family

Siemens plans Osram spinoff

Cree announces LEDs for directional applications

Philips introduces LED linear and spotlight module

25 FUNDING+PROGRAMS

Digital Lumens closes $10 million round of investment to support continued expansion

Rubicon Technology closes $25 million secured revolving credit facility

SEMI publishes HB-LED standard relating to sapphire substrates

DOE publishes new Caliper reports and year in review for the program

ISSUE 58

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Page 6: LED_Feb_2013

4 FEBRUARY 2013 LEDsmagazine.com

commentary

SENIOR VICE PRESIDENT Christine Shaw

& PUBLISHING DIRECTOR [email protected]

EDITOR Maury Wright [email protected]

ASSOCIATE EDITOR Nicole Pelletier [email protected]

ASSISTANT EDITOR Skyler Frink

[email protected]

CONTRIBUTING Tim Whitaker

EDITOR [email protected]

MARKETING MANAGER Jennifer Landry

PRESENTATION MANAGER Kelli Mylchreest

PRODUCTION DIRECTOR Mari Rodriguez

SENIOR ILLUSTRATOR Christopher Hipp

AUDIENCE DEVELOPMENT Debbie Bouley

EDITORIAL OFFICES PennWell Corporation,

LEDs Magazine

98 Spit Brook Road, LL-1

Nashua, NH 03062-5737

Tel: +1 603 891-0123

Fax: +1 603 891-0574

www.ledsmagazine.com

SALES OFFICES

SALES MANAGER Bob Collopy

(US EAST COAST) [email protected]

Tel. +1 603 891 9398

SALES MANAGER Allison O’Connor

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Tel. +1 480 991 9109

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Tel. +44(0)117 946 7262

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(CHINA & HONG KONG) [email protected]

Tel: +852 2838 6298

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Tel: 022846716

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CORPORATE OFFICERS

CHAIRMAN Frank T. Lauinger

PRESIDENT AND CEO Robert F. Biolchini

CHIEF FINANCIAL OFFICER Mark C. Wilmoth

TECHNOLOGY GROUP

SENIOR VICE PRESIDENT Christine A. Shaw

& PUBLISHING DIRECTOR

SUBSCRIPTIONS: For subscription inquiries:Tel: +1 847 559-7330; Fax: +1 847 291-4816;e-mail: [email protected]; ledsmagazine.com/subscribe

We make portions of our subscriber list available to carefully screenedcompanies that offer products and services that may be important for your work. If you do not want to receive those offers and/or information via direct mail, please let us know by contacting us at List ServicesLEDs, 98 Spit Brook Road LL-1, Nashua, NH 03062.

Copyright © 2013 PennWell Corp (ISSN 2156-633X). All rightsreserved. Contents of this publication may not be reproduced in any form without prior written consent of Publishers.

Color science is an incredibly complex

topic. I must say that I underestimated

the importance of color science in terms

of the ability of LED manufacturers and

solid-state lighting (SSL) lamp and lumi-

naire manufacturers to deliver high-qual-

ity products. I’m nearing the end of three

years covering the LED and lighting space,

but still learning something new every day.

And I’d highly recommend that you peruse

the fourth installment in our color science

series in this issue (p. 57).

Indeed, if you haven’t been following

the series, you might go back and read the

entire series even if you started a prior one

and decided the topic was just too complex.

Th e article in this issue includes web links to

each of the prior articles.

George Kelly, who manages Avnet’s Light

Lab, has done an excellent job on the series.

I’ll concede that I found the first couple

of articles very technical and difficult to

understand. And many of us will never use

the math described. But the end of the third

article and the one in this issue brought the

theory into the light of real product design.

It turns out that it’s really important

to understand why two light sources that

are metamers of one another — they have

the same eff ect on the eye even though the

spectral power distribution may be vastly

different — won’t necessarily render col-

ors equally well. Th e light refl ected from an

object that’s illuminated by the two diff erent

sources will not be metamers of one another.

It’s that ref lected light and the eye

response that matters. And in the SSL indus-

try we face confl icting goals of delivering

high effi cacy, excellent color rendering, and

warm color temperature. Th e article in this

issue covers approaches to that task.

I sure hope to convince George to write

one more article in the series, bringing even

more practical examples to light. Mean-

while, he has agreed to do a Webcast on

February 21 on the topic. You can register at

www.ledsmagazine.com/webcasts or view

the archive if you read this column after the

live event.

Th e rest of this issue covers topics rang-

ing from LED manufacturing to new pack-

aged LEDs to driver design to standards to

retrofi t lamps. Th e News+Views section (p. 9)

includes a number of items related to the lat-

est in LEDs, including the move by Toshiba

to a gallium-nitride-on-silicon (GaN-on-Si)

manufacturing process. We also have new

components from Cree, Philips Lumileds,

and Bridgelux.

Retrofi t lamps are among the most popu-

lar topics that we cover with you the reader.

Th at fact led to our choice of cover photo,

and to the feature article on the topic (p. 33).

Modular light engines are becoming

increasingly popular in SSL product design,

whether the module is a proprietary design

or based on an industry standard such as

Zhaga. You will fi nd modular coverage in

News+Views, in the Focus On feature (p. 49),

and in the Last Word column (p. 76) that was

written by Zhaga General Secretary Menno

Treff ers. Treff ers will also have presented a

Webcast on Zhaga’s progress by the time you

read this, but you can view the archive at the

prior Webcast link if you have missed it.

Please enjoy the issue. And I look forward

to seeing you at Strategies in Light. Come by

our booth and say hello.

Maury Wright, EDITOR

[email protected]

Complex color science underlies good SSL products

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Page 8: LED_Feb_2013

6 FEBRUARY 2013 LEDsmagazine.com

ADVERTISERS indexAlpha ..................................................... 47

American Bright Optoelectronics............. 14

Bayer Material Science, LLC ...................53

Cirrus Logic ............................................ 24

Cree Inc. .............................................. CV4

CSA International ................................... 13

EBM-Papst Inc. ........................................ 7

Edison Opto Corporation ........................ 23

Epistar ..................................................... 1

ERG ....................................................... 70

Future Electronics Inc. ............................ 32

GKN Sinter Metals ................................. 70

Global Lighting Technologies .................. 37

Hangzhou Najing Technology Co. Ltd. .....12

Indice Ecotech ....................................... 61

Indium Corporation of America ............... 21

Instruments Systems GmbH ................... 11

Inventronics (Hangzhou) Inc. ................... 15

Konica Minolta Sensing Americas ........... 71

Lambda Research Corporation ............... 16

Lauren Manufacturing ............................38

Ledlink Optics Inc. .................................. 19

Lightfair International .............................48

Matrix Lighting Limited, Hong Kong .......CV2

MBN GmbH ............................................ 17

Metal Coaters ............................ 27, 29, 31

NMB Technologies Corporation ............... 55

Optronic Laboratories Inc. ......................46

Orb Optronix ........................................... 52

Philips Lumileds ....................................... 2

Proto Labs Inc. ....................................... 39

Recom Power Inc. ............................ 73, 75

Roal Electronics USA Inc. ....................... 71

Seoul Semiconductor .............................30

Shanxi Guangyu LED ............................. 18

Lighting Co. Ltd.

Shat-R-Shields ....................................... 42

Shenzhen Baikang Optical Co. Ltd. .............

5 Shenzhen Refond ............................ 28

Optoelectronics Co. Ltd.

Sichuan Jiuzhou Electric ........................43

Group Co. Ltd.

Signcomplex Limited .............................. 67

TE Connectivity ......................................44

The Bergquist Company ........................... 8

Thomas Research Products ....................68

Topco Green Synergy Group ................... 51

Underwriters Laboratories ......................35

Unilumin Group Co. Ltd. .......................... 20

Verde Designs ........................................ 71

FEATURED event

| online

Webcast

Understanding how Zhaga Books enable a

modular approach to SSL product design

http://ledsmagazine.com/features/9/12/10

The Nector S Power System - The

Intelligence in Luminaire Design

http://ledsmagazine.com/features/10/1/1

Whitepaper

Power LED Electrical, Thermal

and Optical Characterization

http://ledsmagazine.com/whitepapers/28/

Thermal Simulation Simplifi es LED

Luminaire Development

http://ledsmagazine.com/whitepapers/27/

Thermal Simulation and Characterization

Optimizes LEDs for Automotive Applications

http://ledsmagazine.com/whitepapers/26/

LED China

March 1-4, 2013

Guangzhou, China

LRC 25th Anniversary

March 20, 2013

Troy, NY

Lightfair International

April 23-25, 2013

Philadelphia, PA

China Lighting Expo

April 25-27, 2013

Beijing, China

Singapore International LED/OLED

Technology Show

May 7-9, 2013

Singapore

LED Expo Thailand

May 23-25, 2013

Bangkok, Thailand

SPARC International Lighting

June 3-5, 2013

Sydney, Australia

The LED Show

August 13-15, 2013

Las Vegas, NV

LED Japan Conference & Expo/

Strategies in Light

October 16-18, 2013

Yokohama, Japan

MORE: www.ledsmagazine.com/events

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Page 9: LED_Feb_2013

Thermal management is a key factor that limits the lumen output and efficiency of an LED lightsource. While as much as 80 percent more energy efficient than traditional incandescent lighting, the LED components still create a considerable amount of heat. If this heat is not dissipated properly, the quality of light and life expectancy of the LED lightsource decreases dramatically.

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 that are superior to passive heat sinks and can raise performance while reducing the size of the lighting fixture. With inaudible noise performance and industry-leading German engineered reliability, ebm-papst can provide the perfect solution for your LED cooling problems

To find out more about custom Active Cooling Solutions, visit info.ebmpapst.us/ActiveCoolingor speak with an application engineer at (860) 674-1515

the engineer’s choice

the spotlight shines on efficiency

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________________________

Page 10: LED_Feb_2013

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Call 1.800.347.4572 or visit www.bergquistcompany.com/preapplied FREE T-Clad® PASample Board

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Page 11: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 9

viewsn

ew

s

Lynk Labs has announced a new chip-on-board (COB) mod-

ule in its SnapBrite family of products that for the fi rst time

relies on mid-power LEDs combined with AC-driver cir-

cuitry. Th e 114-mm-diameter SR114 solid-state lighting (SSL)

module accepts 120-VAC input direct from the power line

and delivers 2000 lm at an operating temperature of 65°C.

Th e new module achieves 100-lm/W effi cacy based on the

mid-power LEDs used and the effi ciency of AC-drive technol-

ogy that eliminates a power conversion stage relative to more

typical DC-driven LEDs. “Th e 100 lm/w result includes all

the required drive and protection circuitry to run the mod-

ule direct from the mains,” said Chick Huber, vice president

of business development at Lynk Labs.

Th e SR114 is the fi rst of a number of products that will

use the general design captured in the new module. Th is

fi rst product features a 3800K CCT and CRI of 83, and when

dimmed, using a legacy triac or phase-cut dimmer, delivers a

warmer color temperature mimicking an incandescent lamp.

CEO Mike Miskin said that the company has a number of

options in how to implement the dim-to-warm technology

including using some amber or red LEDs. Th is fi rst design,

however utilizes two channels. One channel uses 4000K

LEDs and the second uses very warm 2200K LEDs.

At full brightness, the 4000K LEDs deliver the bulk of the

light and the enhanced effi cacy that’s common in higher-

color-temperature LEDs. As the product is dimmed to lower

drive currents, energy usage is generally decreased and the

warm-CCT LEDs contribute more of the light mix.

Th e module delivers a 120° beam pattern that enables its

use in applications such as downlights, fl ush-mount fi xtures,

and ceiling fans. Miskin said, “Now that we have reached 100-

lm/w plug top effi ciency with incandescent quality dimming,

AC LEDs can fi ll the need for cost-sensitive, form-factor-chal-

lenged lighting applications with high system effi ciency.”

The initially available SR114 uses Epistar mid-power

LEDs. At press time the LEDs had not been fully LM-80 qual-

ifi ed. Miskin said, however, that such tests are ongoing and

that the qualifi cation should be in place around mid-Feb-

ruary. He also added that based on customer requirements,

Lynk Labs can utilize a variety of LED types to meet specifi c

application needs. ◀

MORE: www.ledsmagazine.com/news/10/1/10

LED MODULE

Lynk Labs LED light

engine dims to warm

SILICON LEDS

Toshiba announces GaN-on-Si LED production startToshiba announced in December that it began

producing white LEDs on 200-mm (8-in) sil-

icon substrates. Th e TL1F1 1W gallium-on-

silicon (GaN-on-Si) LED is the fi rst product

and will deliver a maximum of 112 lm at 350-

mA drive current. Th e combination of larger

wafers and access to automated back-end

manufacturing tools in depreciated IC fabs

has the potential of lowering the cost of LEDs

and accelerating SSL deployment, although obstacles remain in

reaching the optical effi ciency of sapphire-based LEDs.

Subsequent to the announcement of production start, Toshiba

posted data sheets that reveal that the GaN-on-Si LEDs will ini-

tially come in a choice of 3000K, 4000K, 5000K CCTs (www.leds-

magazine.com/news/10/1/3.) Th e 5000K cool-

white LED comes in 70 and 80 CRI, and the

70-CRI TL1F1-NW0 off ers the top effi cacy spec

mentioned previously. Both the 4000K TL1F1-

WH1,L and 3000K TL1F1-LW1,L deliver 84

lm/W. And both off er a CRI of 80.

The efficacy figures don’t match the lat-

est sapphire-based LEDs. For comparison,

Cree announced the new XM-L2 LED family

recently that is similar in size (p. 12). Th e Cree LED measures 5×5

mm while the Toshiba LED measures 6.4×5 mm. Cree said the

XM-L2 LED can deliver 186 lm/W in cool white at 350-mA drive

current. But if the Toshiba LEDs deliver the anticipated reduction

in costs, the products could do very well. » page 10

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Page 12: LED_Feb_2013

10 FEBRUARY 2013 LEDsmagazine.com

news+viewsToshiba from page 9

We’ve been expecting more news from

the GaN-on-Si players throughout the

fall. Azzurro Semiconductors has been

attacking the problem building tem-

plate wafers that have the base GaN layer

applied, upon which LED companies can

then build their own LED structures.

Th at company has been linked to both

Osram Opto Semiconductors (www.leds-

magazine.com/news/9/1/19) and Epistar

(www.ledsmagazine.com/news/9/10/9).

Partners Lattice Power from China and

Plessey Semiconductors from the UK are

also working on the technology (www.

ledsmagazine.com/news/9/6/12). Lattice

had claimed that it was in production of

such devices back in the summer, but SSL

products using such LEDs haven’t been in

evidence. ◀

MORE: www.ledsmagazine.com/news/9/12/18

BUSINESS

Konica Minolta buys Instrument Systems

Instrument Systems GmbH, one of the LED

industry’s best-known light-measurement

companies, has been acquired by Konica

Minolta Optics, Inc., eff ective December 1.

Instrument Systems was founded in 1986 by

its president, Richard Distl, and is based in

Munich, Germany. Th e company supplies

a comprehensive range of light measuring

products for industrial and research applica-

tions. Key applications are LED and display

measurement, as well as spectroradiometry

and photometry. Th e subsidiary company

Optronik Berlin GmbH is also included in

the sale.

Instrument Systems has posted very

strong growth in recent years, and its

2011/12 fi nancial year, which closed in June

2012, produced the best results since the

company was founded. Combined sales with

the Optronik Berlin subsidiary rose by 27%

to EUR 30.3 million ($39.6 million), up from

EUR 23.9 million in the year ended June 2011.

Konica Minolta Optics was interested in

Instrument Systems reputation in the LED

fi eld. Toshihiko Karasaki, president of Kon-

ica Minolta Optics, said: “Our goal is to have

a leading global position in all our corporate

divisions and to integrate international tal-

ent within our group. Instrument Systems

is the best company in LED lighting mea-

surement to consistently implement this

strategy.”

The acquisition of Instrument Sys-

tems came several weeks after CSA Group

acquired LED testing company Orb Optronix

(www.ledsmagazine.com/news/9/11/12). ◀

MORE: www.ledsmagazine.com/news/9/12/6

PACKAGED LEDS

Philips Lumileds announces workhorse Luxeon T family

Philips Lumileds has introduced the new

Luxeon T series of high-power LEDs that tar-

get SSL applications with directional-beam

requirements including downlights, and

MR16 and PAR retrofi t lamps. Th e LEDs set

new effi cacy milestones for Lumileds achiev-

ing 140 lm/W at 350 mA of drive current.

Lumileds CEO Pierre Yves Lesaicherre

emphasized that Lumileds considers the

Luxeon T much more than an evolution of

the Lumileds family saying, “Th e Luxeon T

is going to be the workhorse in terms of high

effi cacy.” Clearly Lumileds expects Luxeon T

to be the product of choice for applications

in which the LED is expected to produce

maximum forward light.

Lumileds claims several breakthroughs

for the new series beyond effi cacy, includ-

ing what it says is an industry-lowest 2.7V

forward voltage and 3°C/W thermal resis-

tance. Product line director Kathleen Hart-

nett said that only one other LED maker

has reached 2.8V and that most are at 3V or

above. Th e lower forward voltage simplifi es

the thermal design – especially critical in

space-constrained directional lamps such

as MR16 retrofi ts.

Lumileds will offer the LEDs in 3-step

MacAdam ellipse bins, tested at 85°C.

Lesaicherre said that the company is not

matching phosphor tiles with emitters the

way it did in the original Rebel Lumiramic-

based LEDs to reach the tight binning, but

instead controlling the epitaxial (epi) pro-

cess more tightly. “We’ve narrowed the epi

distribution to 1 to 2 bins,” said Lesaicherre .

Indeed, better process control is behind

both the binning and the lower forward volt-

age. Lesaicherre said, “Th e conversion to 6-in

substrates has really helped because we have

more modern equipment.” Specifi cally, he

said they have tighter control of tempera-

ture and gas distribution in the epi process.

Th e LED package measures 3.7×3.7 mm.

Th e prior Luxeon A product targeted simi-

lar applications but features a rectangular

package. Th e new LEDs off er a minimum CRI

of 80, and optionally a CRI of 95, across the

full range of CCTs, including 2700K, 3000K,

3500K, 4000K, and 5000K.

Lime-green LED

Lesaicherre also commented on the mys-

terious lime-green LED that is presum-

ably very important to the function of the

Philips Lighting color-changing Hue lamp

(www.ledsmagazine.com/news/9/10/25).

Lesaicherre was guarded with details but

said that Lumileds had advanced the effi -

cacy of green LEDs that in general has

trailed other colored LEDs industry wide.

Th e Hue lamp uses fi ve of the lime-green

LEDs, four red LEDs, and 2 blue LEDs. Th at

means that the green LED is approach-

ing the effi cacy of the red ones. Th e lime-

green color itself was not the source of the

effi cacy gain. Instead, that lime-green LED

better enables the mixture to deliver the full

color-tunable range according to Lumileds’

Hartnett. Lumileds does plan to off er a lime-

green LED commercially, but is still mull-

ing over plans as to which Luxeon family in

which it will launch the product. ◀

MORE: www.ledsmagazine.com/news/9/12/7

BUSINESS

Siemens plans Osram spinoff

After shelving its plans for an initial pub-

lic off ering (IPO) of Osram, its lighting sub-

sidiary, Siemens has confi rmed that it will

conduct a spinoff of 80.5% of Osram’s shares

(www.ledsmagazine.com/news/9/11/22). A

plan to conduct the IPO of Osram shares was

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We bring quality to light.

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SSL solutions from the world leader in LED measurement

NEW: LGS 250 Goniophotometer

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Find out more about our innovations for SSL :www.instrumentsystems.com/ssl

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Page 14: LED_Feb_2013

news+viewsfi nally shelved in July of 2012.

Th e transaction will result in Siemens’

shareholders receiving one Osram share for

every ten Siemens shares. However, Siemens

still intends to retain a minority stake in

Osram, in which it wants to remain “a long-

term anchor shareholder.” To this end, Sie-

mens AG will retain a 17% stake in Osram

following the spinoff , with the Siemens Pen-

sion Trust holding the remaining 2.5%.

Implementation of the spinoff plans will

require the approval of at least three-quar-

ters of existing shareholders. Th e decision

will be made at the Annual Shareholders’

Meeting scheduled for January 23, 2013, after

we went to press. The Osram IPO (www.

ledsmagazine.com/news/8/3/30) was fi rst

announced in March 2011, and scheduled

for fall 2011. But, as we reported in August

2011, Siemens delayed its Osram IPO plan

(www.ledsmagazine.com/news/8/8/28) due

to adverse market conditions.

Subsequent to the announcement of the

spinoff . Osram off ered some insight on its

plans to both cut cost and invest in SSL. Th e

SSL segment is seen as a key one. At Strate-

gies in Light Europe 2012, Osram’s Christian

Schraft said that the company’s revenue for

fi scal 2011 (ended September 30, 2011) was

around EUR 5 billion, of which around 25%

was from SSL.

Osram will invest in production facili-

ties such as an LED assembly plant in China,

while at the same time selling other plants

that make products using older lighting tech-

nologies. Meanwhile the corporate reorgani-

zation program will result in the loss of an

additional 4700 Osram jobs by 2014 on top

of the 1900 jobs cut worldwide in fi scal 2012.

Most of the cuts that will be implemented

both in Germany and internationally are

aimed at production facilities with products

at the end of their product life cycle, or the

closure of smaller plants with lower sales.

Th e company plans to invest “a low three-

digit million euro fi gure” over the coming

years in the assembly plant located in the

Chinese province of Jiangsu. Th is plant is

in its fi nal completion stage, and its 1700

employees will manufacture products for

key segments of the Chinese market and the

entire Asia region. In fi ve years’ time, Osram

expects this region to account for around

half of the global general-lighting market.

Wolfgang Dehen, CEO of Osram Licht AG,

pointed out that the reduction in staff is a

natural consequence of switching to newer

lighting technologies, particularly LEDs.

“Compared to traditional products, the depth

of our added value in LED-based products

will be signifi cantly reduced. Consequently,

the personnel increase in the future fi elds

will only partially compensate for the change

in the traditional business,” he said. ◀

MORE: www.ledsmagazine.com/news/9/12/2

PACKAGED LEDS

Cree announces LEDs fordirectional applications

Cree recently announced the XLamp MK-R

packaged LED that integrates four die, and

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Page 16: LED_Feb_2013

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14 FEBRUARY 2013 LEDsmagazine.com

news+viewsthe XM-L2 single-die LED – both for direc-

tional applications. The MK-R measures

7×7 mm and fi ts between the 5×5-mm XM-L

family and the 9×9-mm MT-G family. Th e

5×5-mm XM-L2 is a follow on of the origi-

nal single-die XM-L LEDs and Cree says that

it’s the brightest single-die packaged LED on

the market

Th e new MK-R LEDs deliver as much as

1600 lm at 15W in a 5000K CCT – match-

ing the light output of many larger chip-

on-board (COB) LED arrays for SSL retrofi t

lamps and luminaires (www.ledsmagazine.

com/news/9/12/22). “The light output is

more in line with what you see from a COB

array,” said Cree product marketing man-

ager Paul Scheidt.

In terms of effi cacy, Cree is touting the

MK-R for reaching the 200 lm/W level. Cree

says that the product is the follow-on com-

mercial product to the laboratory 200-

lm/W effi cacy achievement announced in

February of 2010 (www.ledsmagazine.com/

news/7/2/7). “It’s amazing that Cree is able

to achieve a 200 lm/W LED so quickly,” said

Nicola Vendrame, CEO of Linea Light group.

“Th e high effi cacy of the MK-R LED means

that we can drive the LED harder for more

light output without creating heat issues.”

Realistically, however, the LEDs will be

applied at much lower effi cacy levels due

to higher drive current and in many

instances warmer CCTs. For example, at

3000K CCT, 80 CRI, 700-mA drive current,

and 85°C junction temperature, the MK-R

delivers 865 lm at 106 lm/W. And many

designs may drive the

LEDs even harder.

The sing le-d ie

XM-L2 LED, mean-

while, maxes out

at 1198 lm at 3A of

drive current, and

can deliver 186 lm/W

efficacy at a lower

drive current. The

second-generation

design targets direc-

tional SSL applica-

tions ranging from

retrofits for direc-

tional halogen lamps to street lights.

A number of Cree LEDs share the XM-L

moniker that is representative of the pack-

age itself. Th e company off ers both high-volt-

age and multi-emitter LEDs in the overall

XM-L family. Th e new XM-L2 is a follow on to

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Page 18: LED_Feb_2013

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16 FEBRUARY 2013 LEDsmagazine.com

news+viewsthe single die XM-L announced in late 2010

(www.ledsmagazine.com/news/7/11/12).

Cree has announced several such sec-

ond-generation LEDs this year that all off er

SSL product developers the option to rede-

sign a product using fewer LEDs, or boost

the performance of a product using the same

number of LEDs. Moreover, second-genera-

tion LEDs only require 3000 hours of LM-80

testing for SSL products that use the com-

ponents to become Energy Star recognized.

Th e second generation XM-L2 off ers 10%

greater lumen output at a 5700K CCT and 17%

better lumen output at 3000K. Th e products

are binned at 85°C and 700-mA drive current,

and at 3000K deliver 224 lm and 112 lm/W.

Cree emphasized that it’s both the single-

die design and the performance that enables

SSL designers to break new ground. Cree’s

Scheidt said “You can do a 50W MR16 with

just a single LED.” Scheidt compared such

a theoretical MR16 with what he character-

ized as the best performing MR16 SSL lamps

on the market for replacing 50W halogen

lamps. Th e comparison lamps delivered 390-

525 lm using 7-10W of power. Th e theoreti-

cal Cree design would deliver 369 lm at 5W.

While the lumen output is lower for the

theoretical lamp, the beam angle is a tight 9°

whereas the other lamps range from 15-25°.

Th e Cree lamp would deliver CBCP of 7800

cd – more than double the other lamps on

the market. Scheidt said, “Because it’s a sin-

gle die, it’s much more effi cient at turning

lumens to candela.” Th e system effi cacy on

the theoretical lamp is 75 lm/W. ◀

MORE: www.ledsmagazine.com/news/9/12/14

LIGHT ENGINES

Philips introduces LED linearand spotlight modules

Philips Lighting has launched a third-genera-

tion LED-based Fortimo Linear Light Module

(LLM) that targets applications such as out-

door lighting including roadway applications.

Philips also announced a new generation of

the Fortimo Spotlight Module (SLM) utilizing

COB LED technology.

Th e new LED LLM Gen 3 family is avail-

able in a choice of four lumen-output pack-

ages – 1100, 1800, 3000, and 4500 lm. Philips

also off ers a choice of 3000K or 4000K CCT,

and a CRI greater than 70. Th e LED SLM Gen

3 includes 2000- and 3000-lm versions with a

CRI of 90 and high R9 value for applications

such as retail.

Philips, is stressing the vertical illumi-

nance of the LLM products. Increasingly ver-

tical illuminance is proving more impor-

tant than horizontal illuminance in outdoor

applications – especially where detection of

pedestrians is important. Th ere is a discus-

sion of that issue in an article on the Street &

Area Lighting Conference that was in the Fall

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Page 19: LED_Feb_2013

MBN GmbH Balthasar-Schaller-Str. 386316 Friedberg · Germany Tel. +49/8 21/6 00 99-0Fax +49/8 21/6 00 99-99E-Mail [email protected]

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Standard series: CRI > 80, Lumen 3400-3500

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news+views

issue of our sister publica-

tion Illumination in Focus (www.

illuminationinfocus.com/features/3/11/4).

“Th e Fortimo LED LLM provides excellent

vertical illumination for optimal facial rec-

ognition, enhancing that feeling of safety,”

said Marina Kishkovich, product man-

ager outdoor LED lighting for Philips OEM

EMEA. “Municipalities understand that

today’s LED lighting technology not only

delivers fantastic energy savings but also

dramatically improves the quality of life for

residents. LEDs provide clear white light,

which has been proven to improve both per-

ceived and actual safety and comfort in res-

idential and urban lighting.”

Moreover, SSL product developers can

now combine an LLM with a Xitanium

driver and achieve Constant Light Output

(CLO) functionality to combat lumen depre-

ciation over time and save energy. Invariably

lighting designers and specifi ers choose a

product with a lumen-output specifi cation

that will meet the required light level years

in the future – accounting in the specifi ca-

tion process for expected lumen deprecia-

tion. Th e Philips Gen 3 product simply drives

the LEDs at lower current levels early in the

product life and over time driver gradually

increases drive current. ◀

PACKAGED LEDS

Bridgelux introducesVero LED array

Livermore, CA-based Bridgelux has unveiled

the Vero LED array family, which off ers “new

advancements in design fl exibility, ease of

use, and energy effi ciency,” says the com-

pany. Vero is also intended to be a platform

that will enable future integration opportu-

nities for smart sensors and wireless com-

munication technology.

Compared with existing Bridgelux LED

arrays, the Vero family off ers an increase in

effi cacy by up to 20%, a higher fl ux density, and

a simplifi ed assembly process that streamlines

manufacturing and improves overall system

reliability. Th e Vero platform will be available

in four form factors with performance rang-

ing from 800 lm in warm white (3000K) up to

20,000 lm in cool white (5000K). Th ere will be

multiple CCT and CRI options, including the

97 CRI Decor product option. Th e Vero plat-

form is currently being evaluated by Bridgelux

customers and will be broadly commercially

available in the fi rst quarter of 2013.

Th e company says that with the new Vero

platform, more of the manufacturing pro-

cess – building the COB arrays and combin-

ing them with the molded-plastic component

– is automated. Th e array-body confi guration

also makes it easier to add functionality in

the future, for example smart sensors or wire-

less-communication chips.

“Th e Vero product is manufactured using

highly automated processes to reduce cost,

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Page 20: LED_Feb_2013

news+viewsand can be easily upgraded for the smart

applications of the future,” said Jim Miller,

chief sales and marketing offi cer of Bridge-

lux. “Th e Vero array off ers our customers

the manufacturing and design capabilities

they need to open up new design possibili-

ties, while ultimately driving faster adoption

of LED lighting.” ◀

MORE: www.ledsmagazine.com/news/9/12/8

DISTRIBUTION

Future Electronics and Philips Lumileds restructure agreement

Th e long-standing distribution agreement

between Future Lighting Solutions (FLS) and

Philips Lumileds, which kept Philips exclu-

sive to FLS and had FLS sell Philips’ LEDs

exclusively, has been restructured, enabling

Philips to sell its LED products through

other partners, and FLS to distribute other

suppliers’ SSL products.

Unlike other LED manufacturers, such as

Osram Opto Semiconductors and Cree, Phil-

ips has always sold exclusively through FLS.

Th e other supplier that sticks out from the

crowd is Nichia, the largest manufacturer

of packaged LEDs according to Strategies

Unlimited, who only sells directly through

their own network and does not use any

distributors.

Th e exclusive distribution agreement was

intended to last for another four years, with

a new fi ve-year exclusive agreement being

signed in 2011 (www.ledsmagazine.com/

press/31644). However, the companies have

decided to expand into new markets, and

have determined the best way to do that is

to restructure the deal.

“Our restructured agreement allows us to

continue our collaboration with a long-term,

trusted and successful partner. With the new

agreement, we are able to serve the needs of

our growing customer base and carry on our

widespread expansion into new target mar-

kets,” said Pierre-Yves Lesaicherre, CEO Phil-

ips Lumileds.

FLS, meanwhile wasted little time in add-

ing another LED manufacturer to its line card.

Th e distributor and LG Innotek have signed

a worldwide distribution agreement through

which FLS will sell LG Innotek’s entire port-

folio of LED lighting products, ranging from

packaged LEDs to integrated solutions.

“We are excited about LG Innotek ’s

exceptionally strong portfolio of LED prod-

ucts, aggressive technology road map, and

unparalleled quality manufacturing capa-

bilities for the general illumination mar-

ket,” said Gerry Duggan, executive vice

president of Future Electronics. “Th is will

further strengthen our profi ciency in serv-

ing our customers’ growing demand for best-

in-class LED lighting solutions.” ◀

MORE: www.ledsmagazine.com/press/37244

LICENSING

Solais Lighting licenses ByteLight technology

ByteLight has signed a partnership agree-

ment with Solais Lighting as its inaugural

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Page 22: LED_Feb_2013

news+viewslicensed lighting partner. Th is means Solais

Lighting is now licensed to manufacture and

sell ByteLight-enabled LED lamps.

ByteLight-enabled lamps from Solais

Lighting will serve as lights and positioning

beacons by transmitting proprietary signals

that can be picked up by camera-equipped

mobile devices carried by customers, visi-

tors, and workers within venues (www.leds-

magazine.com/news/9/10/12). When signals

are detected, each mobile device can calcu-

late its position without the need for an active

network connection. Th is enables venue own-

ers to deliver local content, interactive maps,

and indoor navigation features to users based

on their location inside the venue. ◀

MORE: www.ledsmagazine.com/press/37248

BUSINESS

GE Lighting acquires Albeo Technology

GE Lighting has signed an agreement to

acquire Albeo Technologies, an LED fi xture

manufacturer based in Boulder, Colorado.

GE Lighting offi cials say the acquisition will

help GE serve as an advisor to enterprise

customers, as well as off er a more complete

and integrated family of LED-based SSL

products. Albeo Technologies was founded

in 2004.

“Some of our biggest customers told us

they wanted a GE-quality solution for high

bay,” notes Maryrose Sylvester, president

and CEO of GE Lighting. “Th is acquisition

accelerates our development of cutting-

edge technologies that brings customers

the energy-efficient solutions they need.

Th at’s what customers get at the end of the

day — a refi ned, highly modular and scal-

able platform that delivers the GE quality

they’ve come to expect.”

Albeo’s range of products includes high

bay and low bay lighting fi xtures as well as

linear, surface-mounted and under cabinet

lighting. Albeo’s products have been recog-

nized with 16 independently judged awards,

including six from the US Department of

Energy (DOE). ◀

MORE: www.ledsmagazine.com/news/9/11/18

FINANCIALS

SemiLEDs reports fi rstquarter results

SemiLEDs, a manufacturer of LED chips

and components, has announced its fi nan-

cial results for the fi rst quarter of fi scal year

2013. Revenue for the quarter was $6.2 mil-

lion, an 8% decrease when compared to the

$6.7 million of revenue in fi rst quarter of fi s-

cal 2012.

“As more of our customers have qualifi ed

our EV products, the demand of our LED

chips and LED components has increased,”

said Trung Doan, Chairman and CEO

of SemiLEDs. “We are seeing pockets of

demand while the overall LED market is still

weak; we continue to manage cost, inven-

tory and spending with a focus on profi t-

able LED sectors to achieve our positive

cash fl ow goal.”

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Page 23: LED_Feb_2013

©2013 Indium Corporation

ASIA � CHINA � EUROPE � USA

www.indium.com

[email protected]

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LEDsmagazine.com FEBRUARY 2013 21

news+viewsTh e company also announced improve-

ments in its EV-LED family with efficacy

hitting more than 130 lm/W for some prod-

ucts. Th e company said epi and chip process

advances resulted in a 10% gain in luminous

fl ux and an 8% decrease in forward voltage. ◀

MORE: www.ledsmagazine.com/press/37387

DRIVERS

Cree announces compatibility program

Cree has instituted a new Driver

Compatibility Program (DCP) for its LED-

based modular light engines that allows

luminaire designers freedom of a larger

choice of drivers and Cree warranty cov-

erage on the light engine. Th e DCP is ini-

tially applicable to the LMH2 SSL mod-

ules. Participating companies include AC

Electronics, Code Mercenaries, Harvard

Engineering, Inventronics, Lutron, NMB

Technologies, Opulent Solutions, Phihong,

Roal Electronics, Thomas Research

Products, and Xenergi Limted. Cree plans

to extend the program both to other mod-

ular products and more driver companies.

Th e biggest benefi t of the DCP is warranty

centric. Previously, Cree limited its warranty

coverage on modular products to luminaire

designs that also utilized Cree drivers. Th e

new program does include Cree drivers in

the approved list. But the warranty cover-

age now applies equally to luminaires that

use other drivers in the program. ◀

MORE: www.ledsmagazine.com/news/10/1/6

BUSINESS

Acuity acquires Adura Technologies

Acuity Brands has acquired the assets of

Adura Technologies, a developer of wire-

less controls and energy management tools.

Terms of the acquisition were not disclosed,

and the acquisition is not expected to mate-

rially impact Acuity Brands’ fi scal 2013

consolidated fi nancial performance.

Adura, which was founded in 2005, has

developed radio frequency mesh network-

ing technology that enables light fi xtures to

communicate with sensors, switches, and

management software. Th e technology is

based on the ZigBee wireless standard.

“Adura’s simple to use wireless technol-

ogy coupled with our broad luminaire port-

folio, Sensor Switch occupancy sensors and

Lighting Control & Design system manage-

ment software will allow for the creation of

intelligent lighting systems that are sim-

ple to use while generating greater energy

savings for our customers.,” said Vernon J.

Nagel, chairman, president and chief exec-

utive offi cer of Acuity Brands. ◀

MORE: www.ledsmagazine.com/press/37388

EXECUTIVE MANAGEMENT

Lighting Science Group and Nualight appoint execs

Lighting Science Group (LSG), an LED

lighting manufacturer based in Satellite

Beach, Florida, has appointed Jeremy Cage

as CEO, eff ective January 2, 2013. Ireland-

based LED lighting company Nualight,

meanwhile, has appointed Per Langholz

as its non-executive chairman.

New LSG CEO Cage is a former senior

executive with PepsiCo, Inc. Cage said that

he intends to accelerate growth at LSG by

“building on the company’s core competen-

cies of excellence in innovation and strong

and diff erentiated brand development.”

Cage added that LSG will “focus on

unleashing the science of light and sustain-

able technologies to markets ranging from

major cities, commercial centers, factories

and retailers in developed markets to entire

cities and villages in developing and emerg-

ing markets. Th ere is much to do, and I am

eager to get started.”

Nualight’s new chairman Langholz is the

former president of Sylvania Lighting Inter-

national, where he led the company to prof-

itable operation and annual turnover of over

EUR400 million. He has over 25 years of expe-

rience in the lighting industry. Langholz suc-

ceeds Eamonn Quinn of the Quinn family

that founded the Superquinn grocery chain.

Quinn will remain on the Nualight Group

board. Quinn welcomed the new appoint-

ment, saying, “As we continue to grow glob-

ally and drive expansion into new market seg-

ments, Per Langholz’s experience will make a

tremendous contribution.”

The Nualight Group is a LED lighting

technology specialist with a core focus on

retail, and has pioneered LED lighting in

the refrigerated cabinets of many leading

grocery retail chains. The company has

gone from startup status 5 years ago to

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Page 24: LED_Feb_2013

for thermal conductivity

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news+viewsemploying over 200 people in three loca-

tions worldwide. Nualight is funded by Cli-

mate Change Capital, ESB Novus Modus,

4th Level Ventures and the Quinn retail

family. ◀

LIFE SCIENCE

Adaptive LED lighting improves aircraft cabin environment

Chronobiologically-adaptive SSL scenarios

in which the color and brightness of light-

ing is varied during long-distance over-

night fl ights results in passengers that sleep

better and are more alert upon arrival.

Partners Osram, Bergische Universität

Wuppertal, the Fraunhofer Institute

for Building Physics, Airbus, and Diehl

Aerospace reached the conclusion of

improved wellbeing attributed to adaptive

LED lighting after tests in a model aircraft

cabin over a period of six days.

The team found that at the start of an

overnight fl ight that warm-white light helps

to stimulate melatonin production and

increases passenger relaxation. Indeed, the

warm lighting was noted to reduce the heart

rate in the test subjects and yield “medically

measureable improvement” in sleep patterns.

Th e study further revealed that blue-rich

cold light in the morning increased alert-

ness. In part, the cooler light suppresses mel-

atonin production.

Th e result for passen-

gers is better produc-

tivity or more enjoy-

ment over the course

of the arrival day after

a long trip.

Both psychologi-

cal and physiological

reactions were ana-

lyzed in the test sub-

jects. Th e team used

medical instruments

to capture data such

as heart rate and

ECG measurements.

Th at data was analyzed alongside assess-

ments completed by the test subjects and

by observers of the tests. Th e team believes

that the work can be applied using intelli-

gent SSL systems in aircraft to help mini-

mize passenger jet lag by maintaining nor-

mal circadian rhythms.

MORE: www.ledsmagazine.com/news/10/1/1

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Page 26: LED_Feb_2013

LEDMAG012013

© 2013 Cirrus Logic, Inc. All rights reserved. Cirrus Logic,

Cirrus, the Cirrus Logic logo designs, TruDim and the

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*Based on internal testing by Cirrus Logic of

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Page 27: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 25

programs funding

Rubicon Technologycloses $25 million securedrevolving credit facility

Rubicon Technology, Inc. (NASDAQ: RBCN),

a leading provider of sapphire substrates

and products to the LED, semiconductor,

and optical industries, has closed a three

year $25 million secured revolving credit

facility with Silicon Valley Bank.

“This undrawn credit facility bolsters

Rubicon’s strong liquidity position,” said

William Weissman, chief fi nancial offi cer of

Rubicon Technology. “We believe it is pru-

dent to establish this additional fi nancial

fl exibility for the future,” he concluded.

Rubicon currently has no debt. Th e terms

and conditions of the credit facility will be

described in the company’s fi lings with the

Securities and Exchange Commission. ◀

» page 26

Digital Lumens closes

$10 million round of

investment to support

continued expansionDigital Lumens rung in the New Year with

150% growth in its customer base and a

further commitment from investors to

support the com-

pany’s success in

LED lighting. The

company had more

than 500 large-scale

installations of its

Intel l igent LED

Lighting System

last year.

Accord i ng to

estimates by Canac-

cord Genuity in

the "Third Cycle

V2.2" the overall

LED lighting mar-

ket grew 94% from

2011 to 2012. Digital Lumens grew much

faster than the overall market as custom-

ers deployed the Digital Lumens solution

– oftentimes with multi-site roll-outs –

based on the company’s growing repu-

tation and demonstrated energy savings.

As it prepared itself for more growth

in 2013, the company has closed a $10

million round of funding from existing

investors including Black Coral Capital,

Flybridge Capital Partners, and Stata

Venture Partners.

“Th ese impressive numbers are proof

that the lighting market is moving rap-

idly to LED, and that Digital Lumens

continues to set the standard for per-

formance, effi ciency, and value with our

customers,” said Tom Pincince, President

and CEO of Digital Lumens. “While we

have established a leadership position

in the industrial vertical, our integrated

intelligence is applicable to the entire

lighting market. We will use this latest

investment to accelerate our expansion

into new segments and international

markets, and to further develop our

product and service off erings.” ◀

SEMI publishes HB-LED standard

relating to sapphire substratesTh e HB-LED Standards Committee of SEMI,

the global semiconductor industry associa-

tion, has approved its fi rst LED-related stan-

dard, entitled “SEMI HB1: Specifications

for Sapphire Wafers Intended for Use for

Manufacturing High Brightness-Light

Emitting Diode Devices.”

Developed by the HB-LED Wafer Task

Force, SEMI HB1 defi nes and specifi es the

physical geometry of 150-mm-diameter sap-

phire wafers used in HB-LED manufactur-

ing. HB1 covers dimensional, wafer prep-

aration, and crystallographic orientation

characteristics, as well as the

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Page 28: LED_Feb_2013

26 FEBRUARY 2013 LEDsmagazine.com

appropriate measurement methods.

The document was approved by the HB-

LED Committee during the North Amer-

ica Fall 2012 meetings, recently completed

procedural review and was to be published

in January 2013.

Improving manufacturing eff iciency

and reducing cost are critical to enabling

high-volume LED manufacturing, and

150-mm sapphire wafers represent a key

inf lection point.

Five categories of single-crystal, single-

side polished sapphire wafers are covered

in HB1, including: fl atted 100-mm diame-

ter, 650-μm thick, polished c-axis sapphire

wafers; fl atted 150-mm diameter, 1000-μm

thick, polished c-axis sapphire wafers; fl at-

ted 150-mm diameter, 1300-μm thick, pol-

ished c-axis sapphire wafers; notched 150-

mm diameter, 1000-μm thick, polished

c-axis sapphire wafers; and notched 150-mm

diameter, 1300-μm thick, polished c-axis

sapphire wafers.

SEMI believes that in order to reach the

full potential of LEDs, there is a need for the

global LED manufacturing supply chain to

collaborate on industry standards to elim-

inate unnecessary costs, and better enable

equipment and process innovation.

With this in mind, key industry stake-

holders created the SEMI HB-LED Stan-

dards Committee in late 2010. Th e Com-

mittee and Task Forces are comprised of

industry leaders in HB-LED devices, sap-

phire wafers, MOCVD wafer processing,

and key equipment and materials suppli-

ers to the LED industry.

Since formation, the HB-LED Committee

has initiated Task Forces on wafers, carri-

ers, assembly and automation. Committee

co-chairs are: Iain Black (Philips Lumileds),

Chris Moore (Semilab), David Reid (Silian),

and Bill Quinn (WEQ). Ongoing activities

include the following:

HB-LED Wafer Task Force (TF)

Th e HB-LED Wafer TF is already developing

a revision proposal for further refi nements

to the HB1 standard including:

• patterned sapphire substrate (PSS)-ready

specifi cation for 100-mm and 150-mm wafers

• double sided polished wafer specifi cations

• defi nitions and specifi cations of impurities

and defects (wafer and bulk)

• laser marking and identifi cation

specifi cation

• bow, warp measurements.

HB-LED Equipment

Automation Task Force

The Equipment Automation TF has

developed draft document 5420A enti-

tled “Specification for Cassettes for 150

mm Sapphire Wafers Used in HB-LED

Manufacturing.”

To minimize impact to the industry, the

TF is leveraging existing 150-mm silicon

cassette standards with minor revisions.

Th is will allow interoperability with exist-

ing 150-mm equipment and any other 150-

mm compatible products.

Considerations were taken around the

cassette’s pocket size and spacing so that the

sapphire wafers can be successfully trans-

ferred between cassettes with automated

handling equipment. A cassette standard

will also enable standardization of load

ports and transport systems.

HB-LED Impurities &

Defects Task Force

Th e Impurities & Defects TF will begin

experiments and test methods based on

responses to a survey aimed at identifying

sapphire wafer defects that are relevant

or important to HB-LED manufacturing,

as well as inspection techniques that can

be applied to identify, measure, or prevent

such defects.

Upcoming Meetings

The HB-LED Wafer TF, Equipment

Automation TF, and Impurities & Defects

TF will be meeting in conjunction with the

Strategies in Light conference (February

12-14, 2013) in Santa Clara, California.

Taiwan LED Safety Task Force

The LED Safety Task Force was char-

tered in late 2011 under the Taiwan EHS

(Environmental, Health, and Safety)

Committee to develop specifi cations and

guidelines related to LED manufacturing

equipment. Th e activities of the task force

will result in the development of an EHS

industry standard for equipment suppliers,

raw material suppliers, module makers and

other involved parties. ◀

DOE Caliper report evaluates

LED PAR38 lamps

A recent Caliper report from the US

Department of Energy (DOE), which is

number 20 in the series, evaluates the

independently-tested photometric perfor-

mance of 38 LED PAR38 lamps.

Th e Caliper program supports testing of a

wide array of solid-state lighting (SSL) prod-

ucts available for general illumination. A

summary of the series 20 results is available

for download from the DOE SSL website.

Th e series 20 results show signifi cant

improvement versus earlier Caliper testing

of similar products. All of the LED PAR38

lamps tested off er substantial energy sav-

ings compared to halogen PAR38 lamps.

Some of the LED lamps had higher effi -

cacy than compact-fl uorescent (CFL) or

ceramic-metal-halide (CMH) versions.

Th e lumen output of many of the prod-

ucts was equivalent to 40W to 90W halo-

gen PAR38 lamps, and all emitted between

388 and 1363 lm. Effi cacy of the LED lamps

ranged from 26 to 79 lm/W, although all

except one of the products was between 44

and 79 lm/W.

Further, LED products are available that

cover the full range of conventional PAR38

beam angles, and that have appropriate

color quality, lumen output, and center

beam intensity.

The LED PAR38 lamps had luminous

intensity distributions ranging from narrow

(8° beam angle) to very wide (64° beam angle);

the suitability of these distributions depends

on the application, but the availability of nar-

row distributions is an important fi nding.

In an improvement compared to earlier

testing, 37 of the 38 products had a power

factor higher than 0.70.

However, more options within specifi c

product families would be benefi cial, and

LED lamps with higher lumen output may

be necessary for specialty applications.

And, as usual, lower prices would also be

benefi cial to enhance the penetration of

LED lamps into the market.

Beginning in 2012, each Caliper sum-

mary report focuses on a single product

type or application. Products are selected

with the intent of capturing the current

state of the market—a cross section rang-

ing from expected low- to high-perform-

ing products—with the bulk characteriz-

ing the average of the range. ◀

SEMI from page 25

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Page 29: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 27

programs funding

Next Generation Streetlights guide covers

LED technology to fi nancing

The Bay Area Climate Collaborative,

Energy Solutions, the California Lighting

Technology Center, and Public Financial

Management have partnered to produce a

guidebook for municipalities considering a

transition to SSL roadway lighting.

"Next generation streetlights: LED tech-

nology and strategies for action" is a new

guidebook intended to help municipalities

that are considering

installation of LED-

based street lights.

Th e Bay Area Climate

Collaborative (BACC)

and Energ y Solu-

tions co-authored

the solid-state light-

ing (SSL) guide with

assistance from the

California Lighting

Technolog y Center

(CLTC) at the Uni-

versity of California

at Davis and support

from Public Financial

Management.

Th e guide was written

primarily to assist San Fran-

cisco Bay area municipalities that are con-

sidering SSL installations. But the guide

would be informative to any municipality

considering LED-based roadway lighting.

Th e document covers topics ranging from

the basics of LED lighting technology to the

use of adaptive controls in roadway applica-

tions to fi nancing options for SSL projects.

Th e BACC and Energy Solutions have iden-

tifi ed more than 240,000 municipally-owned

fi xtures in the Bay area that are ripe for con-

version. "Upgrading these street lights to

LEDs would yield annual energy savings of 60

million kWh, enough to power 10,000 single-

family California homes,” said Ted Pope, vice

president at Energy Solutions. "Furthermore,

advanced controls networks that tune light

levels, communicate status and provide other

features can generate additional energy and

maintenance savings through smarter man-

agement of street-light systems."

A number of SSL manufacturers and the

Pacifi c Gas and Electric utility are also part-

ners in the BACC-led Next Generation Street-

light Initiative that's focused on cata-

lyzing the conversion of more than

200,000 lights.

Th e partners announced the new guide

at the recent Next Generation Streetlight

Workshop held in Hayward, CA. Hay-

ward is in the process of upgrading 8000

street lights to SSL. "We know how benefi -

cial the upgrade to advanced street lights

is to a city’s budget, to the environment,

and to public safety," says Morad Fakh-

rai, director of public works for the City of

Hayward. "We also know that a successful

transition can be complex. Th is guide is a

great resource and will be of great benefi t

to all forward-thinking cities."

"A city such as Hayward with 8000 lights

could save $450,000 per year or more in power

and maintenance costs, improve lighting qual-

ity, and reduce its climate impacts," said Rafael

Reyes, BACC executive director. "Th is is a good

time for cities to act given the currently sub-

stantial incentives available, low cost of fi nanc-

ing and very attractive payback times."

Th e new guidebook is available in PDF form

on the BACC website. Th e BACC is a public-

private initiative of the Silicon Valley Leader-

ship Group with backing from Bank of Amer-

ica, Pacifi c Gas & Electric, and more than 70%

of the municipalities in the Bay area.

Previously GE Lighting announced a part-

nership with the BACC. "LED lighting has

been identifi ed as a top opportunity for excel-

lent fi nancial, community and environmental

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__________________

Page 31: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 29

programs funding

benefi ts, and GE has tremendous expertise on

effi cient lighting solutions," said Rafael Reyes,

executive director of the Bay Area Climate

Collaborative. "Th rough our collaboration,

we will help local governments save millions

of dollars that can be reinvested to strengthen

the regional economy."

GE Lighting will support the program

with outreach programs and sharing of the

expertise that it has gained through many

SSL street-light projects such as the ongoing

Las Vegas project that covers 50,000 fi xtures.

While we regularly write about impressive

numbers of LED street lights being installed

in the US and around the world, the transi-

tion is in its infancy. ◀

DOE compares LED pendants

Th e DOE has also completed a Caliper report

covering LED pendant lighting, testing 11

linear products available in both an LED and

fl uorescent versions. Fluorescent products

typically off er more diff erent confi gurations,

whereas LED are typically only available in

one or two lumen packages. Th e report sug-

gests that, moving forward, LED products

would benefi t from a wider range of lumen

packages.

Th e luminous effi cacy of LED linear pen-

dants is often higher than the effi cacy of

their fl uorescent counterparts. Th e speci-

fi ed effi cacy for the surveyed LED luminaires

reached 85 lm/W, with measured effi cacy for

the products going as high as 79 lm/W. ◀

EPA progresses on Energy Star luminaires

and lamps specifi cationsTh e US Environmental Protection Agency

(EPA) has published version 1.2 of the

Energy Star luminaires specifi cation and

released the third draft of version 1.0 of

the Energy Star lamps specification –

both of which are being driven by the SSL

transition.

Th e EPA continues to tune its Energy

Star specifications for lamps and lumi-

naires, and manufacturers of LED-based

lighting products that want to seek Energy

Star status have new targets. Version 1.2

of the Energy Star luminaires specifi cation

guides the design of directional and non-

directional SSL fi xtures while the Energy

Star lamps specifi cation that is in draft

form targets retrofi t lamps.

Th e lamps and luminaires specifi cations

aren't specifi c to SSL products, but LED-

based products are driving much of the

work in the specifi cations, because of the

effi cacy and light output advancements in

SSL. Still, the EPA has backed off a bit in the

planned effi cacy ramp.

Version 1.2 of the luminaires specifi ca-

tion is available on the EPA website. One

major change is the elimination of the pre-

viously announced plans to mandate effi -

cacy of 70 lm/W by September 1, 2013.

The EPA has left the requirement at 65

lm/W until it considers version 2.0 of the

specifi cation.

Th e new version also eases light output

requirements of some directional lumi-

naires such as ceiling-fan lights with

multiple heads and chandeliers. In such

non-directional products, the specifi ca-

tion calls for measuring the performance

of the light source, whereas in directional

products the performance of the inte-

gral luminaire is measured. Th e agency

noted that in the excepted applications,

the prior 800-lm minimum requirement

isn't appropriate.

Th e third draft of Energy Star lamps ver-

sion 1.0 test methods has been released as

well. Th ese test methods include the ele-

vated temperature life test, ambient tem-

perature life test, elevated temperature

light output ratio, start time, and run up

time. The new draft has language that

clarifi es the products that are and are not

eligible for Energy Star recognition. Th e

Elevated Temperature Life Test has been

modifi ed. Moreover, there are changes in

luminous intensity distribution require-

ments and in uniformity of color over angle

requirements. ◀

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___________________

Page 33: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 31

Rancho Cucamonga, CA

800-841-4565

Jackson, MS

800-858-1203

Marietta, GA

800-669-0624

Middletown, OH

877-669-3602

programs funding

Caliper 2012 year in review

Th e DOE has released a year-in-review of

its Caliper program, and suggests that LED

products are becoming more effi cient, less

costly, and producing more light than ever

before.

In 2012, Caliper reports focused on a sin-

gle product type, rather than using a num-

ber of diff erent lamps and luminaires in a

single summary report. By doing this Caliper

could provide more in-depth analysis of the

performance baseline of conventional prod-

ucts and the expectations for LED products.

Th e LED products that were examined in

2012 included fl oodlights, AR111/PAR36 lamps,

downright retrofi ts, BR30/R30 lamps, linear

pendants, wallwashers, and PAR38 lamps.

Th e DOE has reviewed years of Caliper

data and highlighted some trends, although

the agency warns that some of the points

may not be statistically meaningful. Still

the comparison shows where the SSL seg-

ment is trending.

One trend the DOE has noticed include

the rise of luminous effi cacy over the years,

though 2012 saw a drop of 3 lm/W (from

55 lm/W) that may have been caused by

the inclusion of recessed downlight wall-

washers, which generally have a lower effi -

cacy regardless of their light source. Other

trends include a steady rise in CRI, with

the average rising 2 points this year to 82,

increased availability of appropriate CCTs,

and an increase in input power from a mean

of 7.7W (lamps only) in 2011 to 14.2W (lamps

only) in 2012.

Caliper has also identifi ed some of the

possible limitations current LED off erings

have. Th ese limitations include LED prod-

ucts lacking the modularity of conventional

products, a lack of lumen package options,

the initial cost of LEDs, and inaccurate man-

ufacturer claims.

When compared to other years, the 2012

Caliper reports suggest that price is being

reduced, and the lumen output of LED lamps

is increasing. Th e Caliper data shows that,

while LED products have gotten much more

competitive since 2006, there is still con-

stant improvement in quality, cost effec-

tiveness, effi cacy, and control features.

DOE updates the latest L Prize lamp

test results, rebate offersTh e DOE has released another update of

its testing of the Philips Lighting LED

60W-equivalent retrofi t lamp that won

the L Prize. Th e tests have reached what

the agency considers the equivalent of

18 years of household use with no fail-

ures. Th e DOE also released a summary

of rebates available for the SSL product

that range as high as $20 per lamp.

After 20,000 hours of operation, the

full lot of 200 sample lamps are all still

operating. Moreover, the DOE said that

average lumen maintenance remains

above 100% of their initial output. The

tests are being conducted in an envi-

ronment where the ambient tempera-

ture is maintained at 45°C.

Based on typical household lamp use

that averages three hours per day, the

DOE says that the 20,000 hours is equiv-

alent to 18 years of residential usage.

Such a lifetime makes the lamp price

more palatable with Home Depot cur-

rently selling the product for $30.

Of course the price is even more attrac-

tive for consumers that can snare one of

the rebates being off ered by certain util-

ities around the US. Effi ciency Vermont

is off ering a $20 rebate through Home

Depot stores in the state. Th e Southern

Minnesota Municipal Power Agency is

off ering businesses a $20 rebate and con-

sumers a $15 rebate.

Puget Sound Energ y in Washing-

ton State is offering consumers a $10

rebate plus a $5 discount coupon usable

at Home Depot stores, as well as a $20

rebate for business customers. The L

Prize website includes a complete list

with other offers in Illinois, Colorado,

and Massachusetts. ◀

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___________________

Page 34: LED_Feb_2013

Ordering information:

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P������$������07;�0����Q�����Featuring New 54W Dimmable Xitanium Driver for General Lighting Applications

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Page 35: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 33

lighting | RETROFIT LAMPS

LED-based retrofi t lamps remain the

most popular topic in the solid-state

lighting (SSL) industry, despite the fact

that a form factor such as the A-lamp does

little to support the inherent advantages

of LED sources. Still, the huge number of

retrofi t-lamp sockets installed around the

globe make the retrofi t lamp important to

both lamp manufacturers and users looking

to proliferate SSL tech-

nology and save

energy. And while

the basic size and

type of socket may

be f ixed, manu-

facturers are tak-

ing vastly different

approaches to try and

win in what could be a

short-lived market.

Many of the lamp-

design topics we will dis-

cuss here could be exam-

ined relative to many

different types of retro-

fi t lamps. Th e potential list

includes LED-based tubes

designed for linear f luores-

cent sockets and directional

and refl ector products such as PAR, MR, and

BR lamps. In this article, however, we will

focus on omnidirectional A-lamps that are

the most prevalent lamp in use.

You need look no further than at a list of

the most popular articles on the LEDs Mag-

azine website for 2012 (www.ledsmagazine.

com/news/9/12/21) for proof of the appeal of

the topic at hand. More than 25% of the top

20 list had a retrofi t lamp focus.

But ironically, the opportunity for com-

panies to sell retrofi t lamps is inherently

limited. Socket saturation will occur fairly

quickly. As we’ve reported previously, out-

spoken Tempo Industries CEO Terry Walsh

predicted saturation within fi ve years at Th e

LED Show last summer (www.ledsmaga-

zine.com/features/9/10/8).

Saturation will happen for two reasons.

First, demand will drop as long-lasting LED

lamps become predominant and don’t need

to be replaced often. Second, purpose-built

SSL luminaires will make much better use of

LED sources and will become increasingly

popular even in residential applications. For

all of those retrofi t-lamp startups out there

burning through venture money, the mes-

sage had better be get to market quickly. And

for companies such as Philips Lighting, that

may have invested more than anyone in ret-

rofi t lamp development, good job but get your

money back in a hurry.

In actuality, there is still a huge oppor-

tunity. In a report issued in April

2012, Strategies Unlim-

ited repor ted that

there were $2.2 bil-

lion in LED-based ret-

rofi t lamps sold in 2011.

The report projects 30%

annual growth through

2016. But saturation could

happen shortly after the 2016

timeframe.

Lamp design

Having covered the market a

bit, let’s transition to a discus-

sion of the products and design

approaches. We will start with

Philips because of the noted suc-

cess the company has had including

with the US Department of Energy (DOE) L

Prize winning lamp and the latest change to

their design approach.

Philips has built retrofit lamps using

a number of approaches, but is proba-

bly best known for the remote-phosphor-

based designs that have a yellow or orange

tint when powered off . As we covered in a

recent contributed article, remote-phos-

phor designs that combine very effi cient blue

LEDs with phosphor on a secondary optic,

provide an effi cacy advantage over designs

that use phosphor-converted white LEDs

(www.ledsmagazine.com/features/9/7/6).

Moreover, remote phosphor can provide

Varying approaches to LED

retrofi t lamps show no limit

After the incandescent lamp changed little in more than a hundred years, emerging SSL lamps show

remarkably diverse approaches in attempts to replace the incumbent, reports MAURY WRIGHT.

MAURY WRIGHT is the Editor of LEDs

Magazine.

FIG. 1. Philips Lighting has taken different

design approaches on the L Prize-winning

lamp, the EnduraLED family, and the new

Energy Saving LED A19 lamp (left to right).

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34 FEBRUARY 2013 LEDsmagazine.com

lighting | RETROFIT LAMPS

more consistent color main-

tenance because the phos-

phor is not subject to

the heat generated by

the LED, and therefore

doesn’t shift in color

over time.

The Philips remote-

phosphor design was fi rst

revealed several years back

when the company announced

their entry into the L Prize com-

petition for a 60W-equivalent

retrofi t lamp. Th e company fi rst

commercialized the technol-

ogy in the lamps sold under the

EnduraLED and Ambient LED

brands in different parts of the

globe. Later, the company com-

mercialized the L Prize winner that

had to meet higher standards than

the Energy Star-compliant

EnduraLED products.

Fig. 1 shows the L Prize

lamp on the left and the

EnduraLED lamp in the

center. Th e products share

the same shape and both

are based on three illumination chambers

with air-f low channels between the seg-

ments for cooling. Th e LEDs are mounted

near the center axis of the lamp in each

segment on a vertical circuit board that’s

approximately perpendicular to the center

axis. Th e LEDs are directed outward and

slightly upwards and downwards to deliver

an omnidirectional beam.

There are, however, significant differ-

ences in the designs. Th e L Prize lamp uses

a diff erent phosphor composition, and adds

some red LEDs to deliver the combination

of the high 90 CRI required by the L Prize

rules along with effi cacy over 90 lm/W. Th e

lower-cost EnduraLED product uses a phos-

phor that absorbs more of the blue LED light,

still delivers the warm 2700K CCT, but off ers

less lumen output and lower effi cacy.

Philips new architecture

Interestingly, Philips just announced a new

60W-equivalent lamp family at the end of

2012 that maintains the general shape of the

prior lamps, but that is white in the off state

(www.ledsmagazine.com/news/9/12/10). Th e

new design also eliminates the segmented

approach (Fig. 1 on right).

Competitors had cer-

tainly questioned the look

of the remote-phosphor

lamps. And some speci-

fiers would be unlikely

to use the lamps in fi x-

tures where the lamps

are exposed. The Home

Depot retailer even installed

signs near EnduraLED lamps

explaining to customers that

the yellow or orange lamps emit-

ted white light when powered

on. Philips insisted all along that

performance was more impor-

tant than the off -state appearance

of the remote-phosphor lamps. But

the new design could mean that the

company felt pressure to off er lamps

with more of a legacy look.

Todd Manegold, director

of LED lamps marketing at

Philips Lighting, said, “We

have been focused on repli-

cating traditional sources.”

He said the company fi rst

attacked the problem of

delivering equivalent performance and

the warm CCT of incandes-

cent lamps, and now is

addressing aesthetics.

Despite the similar

shape of the lamps,

w h ich M a negold

referred to as iconic

and easily recog-

nized as a Philips LED

lamp, the new Philips

Energy Saving LED A19

lamps are much differ-

ent internally. Th e LEDs

are mounted on a plane per-

pendicular to the center axis

of the lamp, projecting light

upwards into the light chamber.

Th e optic itself must ensure that

the lamps still deliver an omnidi-

rectional distribution. And clearly

the design works, because the

2700K version that Philips calls

Soft White has already gained

Energy Star status and Energy

Star requires an omnidirec-

tional beam distribution.

Philips is still using remote phosphor on

the 2700K lamp, but the phosphor is applied

on an inner dome that isn’t readily visible.

Th e 5000K Daylight version of the lamp sim-

ply uses phosphor-converted LEDs. Mane-

gold said that the company would be updat-

ing its 75W- and 100W-equivalent lamps

to use the new design down the road,

although the company just began shipping

the 100W-equivalent EnduraLED product in

December as we will discuss a bit later.

Best Buy Insignia lamp

While Philips moved to a planar mounting

scheme for its LEDs, another new lamp on

the market, the Insignia lamp from retailer

Best Buy, took yet another approach to ver-

tically mounting LEDs for good light distri-

bution. Insignia is retailer Best Buy’s house

brand for many types of consumer electron-

ics including TVs. In November the company

announced the SSL lamp along with Cree

who is supplying the LEDs for the lamp.

Th e design looks white and somewhat like

a traditional lamp, although you can clearly

see the lamp is broken into three globe seg-

ments separated by what are apparently

cooling surfaces (Fig. 2). What isn’t apparent

is that the LEDs are mounted on the inside

of those surfaces shining at the

globe segment on the oppo-

site side of the lamp. Th ere

is nothing in the center of

the globe. The result is

a well performing 13W

lamp with a good omni-

directional beam and a

price of $16.99 for a 800-

lm 60W equivalent. Best

Buy also off ers a 9W, 450-

lm 40W-equivalent lamp.

Reviews have been gener-

ally positive for the dimming

performance as well. Th e design

team behind the product remains

unknown at this point. While Cree

participated in the announcement,

the company said it did not design

the lamp. The company did per-

form its Thermal, Electri-

cal, Mechanical, Photomet-

ric and Optical (TEMPO)

test suite on the design

(www.ledsmagazine.com/

news/8/9/32). And Best

FIG. 2. The Insignia lamp

from Best Buy mounts Cree

LEDs inside the vertical

cooling surfaces directed at

the globe on the opposite

side of the lamp.

FIG. 3. Rambus has used

a cylindrical MicroLens

light guide implemented

in three segments in an

SSL A-lamp design.

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Page 37: LED_Feb_2013

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Page 38: LED_Feb_2013

36 FEBRUARY 2013 LEDsmagazine.com

lighting | RETROFIT LAMPS

Buy said it is designed to meet Energy Star

requirements and that certifi cation is under

way. Like most of the Insignia products, the

lamp is being made by an unnamed contract

manufacturer.

Rambus MicroLens

Another new approach to retrofit lamps

comes courtesy of Rambus. Th e company is

an intellectual property (IP) specialist that

doesn’t manufacture products but rather

licenses technology to other manufactur-

ers. Its play in the lighting segment is a light

guide technology called MicroLens that car-

ries rays from the LED sources and includes

small optical elements embedded within the

layers of the guide to defl ect some rays and

provide a naturally diff use light.

MicroLens has primarily been used thus

far to develop fl at planar lighting. GE Light-

ing is one licensee and recently announced

a pendant luminaire based on the technol-

ogy (www.ledsmagazine.com/news/9/11/17).

Cooper Lighting and Fern-Howard have also

licensed the technology.

In the case of the A-lamp

that Rambus introduced at

the Consumer Electronics

Show in Las Vegas, Rambus

has manufactured a pilot

run of an end product but

will still look to partners to

ultimately bring the prod-

uct to market. Elite Group

will be the initial source for

a 60W-equivalent A19 lamp

due in the second quarter.

The retrofit lamp uses

three cylindrically shaped

MicroLens segments that essentially form

a cylindrical lamp (Fig. 3). The LEDs are

mounted in a circular fashion around the

base of the lamp shining upwards into the

light guide.

Rambus believes that it has an approach

that will be cheaper to manufacture com-

pared to other LED lamps. “Our unique

design has all the benefi ts of the best LED

technology available and offers a signifi-

cant bill of materials cost savings,” said Jef-

fery Parker, president of the Rambus Light-

ing and Display Technology division.

Th at claim of course depends on the cost

of making the light guide. Moreover, it’s not

clear that the design could meet Energy Star

requirements that require uniform lumi-

nous intensity over a range of 0° to 135° with

0° being the top of the lamp. Th e lamp should

deliver an even beam around the circumfer-

ence of the cylinder. But it’s not clear that it

could generate uniform light upwards and

downwards.

3M LED Advanced Light

Th e Rambus lamp is the second product

announced in the second half of 2012 to use

light guide technology – the fi rst being from

another surprise market entrant 3M (www.

ledsmagazine.com/news/9/8/21). Th e giant

company is a materials specialist, and evi-

dently saw a good chance to use a number

of its materials technologies in a fast-grow-

ing market segment despite the fact that it

hasn’t previously sold lighting products.

The approach depicted in Fig. 4 greatly

simplifi es the driver design, as the driver is

FIG. 4. Materials

specialist 3M was fi rst

to use a light guide in a

retrofi t lamp, mounting

the LEDs in the base.

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Page 39: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 37

lighting | RETROFIT LAMPS

located in the relatively spacious globe. Most

other SSL retrofi t lamps cram the driver into

the base and/or neck of the lamp. The 3M

design allows air to fl ow into the lamp just

above the base and exit through slots in the

upper half of the globe – cooling both the LEDs

and the driver.

Th e LEDs are mounted facing upwards

around the circumference of the neck of the

lamp shining upwards into the light guide.

A number of 3M materials are used in the

lamp including optically clear adhesives

used on the globe. Th e design also uses 3M’s

Enhanced Specular Refl ector material in the

light engine. And the design uses 3M electri-

cal connectors.

Th e result is an 800-lm lamp that is being

sold at many Walmart stores for $25. 3M is

offering both 3000K and 5000K versions.

Th e warm-white version requires ten LEDs

to deliver the specifi ed fl ux, while the cool-

white version uses nine LEDs.

100W-equivalent race

Perhaps the most exciting news over the

course of 2012 in the retrofit lamp area

was the race to off er the LED equivalent

of a 100W lamp. Government regulatory

guidelines around the globe are forcing

100W incandescent lamps from the mar-

ket. Ironically, such regulatory agencies

targeted 100W lamps fi rst because they use

more energy than lower-wattage lamps. But

those higher-output lamps are also harder

to design with LEDs because of the require-

ment of delivering on the order of 1600 lm

and handling the associated thermal issues

– drawing heat away from the LEDs to

ensure reliable operation. Th e industry has

eagerly sought an LED-based alternative.

Back at Lightfair International last May,

we witnessed dueling 100W-equivalent news

releases from the likes of GE Lighting, Switch

Lighting, Philips Lighting, Lighting Science

Group and Osram Sylvania (www.ledsmag-

azine.com/news/9/5/4). Most pledged to be

fi rst to market, but commercial delivery was

far from certain in 2012.

It turns out that Osram Sylvania won the

race by a nose over Philips Lighting (www.

ledsmagazine.com/news/9/11/6). In mid

November some Lowes retail stores had

the Sylvania Ultra LED 20W A21 lamps on

shelves. Philips EnduraLED lamps shipped

to Home Depot starting December 1. Th e

other contenders have yet to ship products.

Sylvania Ultra LED

Th e Sylvania product (Fig. 5) outputs 1600

lm with effi cacy of 80 lm/W. It has a CRI of

80, color temperature of 2700K and is dim-

mable to 10%. Th e company said that based

on the 25,000-hr rated life, the lamp would

save consumers $220 over its life relative to

an incandescent lamp.

“Today’s announcement from Osram Syl-

vania shows a commitment to providing

high quality, energy saving products,” said

FIG. 5. Osram won the race to deliver a

100W-equivalent lamp in the Sylvania

Ultra LED 20W A21 product.

FIG. 6. GE Lighting will use a SynJet

active cooler in its 100W-equivalent A19

lamp due on the market soon.

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38 FEBRUARY 2013 LEDsmagazine.com

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lighting | RETROFIT LAMPS

Phil Rioux, Osram vice president of

lamps and general lighting. “We

have a deep understanding of the

challenges facing businesses and

consumers, such as saving energy

and reducing electricity bills with-

out sacrifi cing quality of light.”

Th e Sylvania design, like many other

SSL retrofit lamps, uses a segmented

architecture that mixes cooling channels

and the optic globe. It is white in the off

state and could probably pass for a legacy

frosted light bulb.

You may note in the product name that the

Sylvania lamp is in the A21 form factor as opposed

to the A19 form factor that is most common in res-

idential incandescent lamps. A21 lamps can have

slightly longer necks than A19 lamps. Th e slight size dif-

ference matters little in many applications because they

both use the same Edison socket base. But A21 lamps won’t

fi t in every application.

Th e Philips 100W-equivalent is also an A21 lamp. It

delivers 1780 lm consuming 22W. Sylvania also wins

the effi cacy race by a nose.

GE Lighting, for its part in the race, said all along

that it would be sometime in 2013 before it delivered

the 1600-lm Energy Smart LED lamp (Fig. 6). But

the company has steadfastly promised an A19 size.

Ironically, the company will add components to the

design to reach the smaller size.

GE has invested in Nuventix and licensed the com-

pany’s SynJet technology that includes active cooling

devices that create pulses of air. GE will use a SynJet in

its 1600-lm lamp and that active cooling will allow the

company to minimize the size of the heat sinks used

and hit the A19 form factor.

Th e architecture comes at a price both in bill of

materials and effi cacy. GE hasn’t said what the lamp

will cost, but the SynJet cooler will increase the com-

ponents costs over passive heat sinks. Moreover, the

1600-lm design will use 27W because the SynJet

does use a small amount of energy.

The startup dilemma

Returning to a theme we struck early on, new players in

the retrofi t lamp space face the challenge of trying to get to mar-

ket quickly with an innovative design, and capturing share prior

to saturation. No company is more instructive in the process than

Switch Lighting.

We featured Switch Lighting on the cover of LEDs Magazine back

in June of 2011 after their lamp design debuted in April of 2011. Th e

design story was very compelling. Th e company would fi ll the globe

of its lamp with liquid to draw heat away from the LEDs. At Th e LED

Show last summer, CEO Tracy Bilbrough revealed the liquid to be sil-

icone based (www.illuminationinfocus.com/news/3/8/3).

Th e company has introduced 40W-, 60W-, 75W-, and 100W-equiv-

alent lamps as well as a novel LED 3-way lamp. Indeed, the company

was the fi rst of the retrofi t lamp players to tout a 100W-equivalent

lamp. But only in the fall of 2012 did Switch began to sell lamps com-

mercially. Th e Switch40 sells for $42.99, the Switch60 sells for $49.99,

and the Switch75 sells for $58.99. Th e Switch100 is priced at $65.99

but still isn’t readily available.

Th e reason for the delays in shipping are basically unknown to

anyone outside the company. Surely the design is complex, and the

pricing supports that fact. Seeing sample lamps over the course of

20 months, it’s apparent that the design went through a number of

changes. Th e LEDs that are mounted facing outward around the cen-

ter of the globe were once installed on aluminum fi ngers. Some type

of printed-circuit board has replaced those fi ngers.

Fortunately for Switch, the company had an early start in the

retrofi t lamp race. Th ey still have an opportunity to make money

assuming the lamps deliver on the promised specs. A startup enter-

ing the market today facing a two year development cycle would

have a tough time recouping the R&D expense with socket satura-

tion looming.

FIG. 7. Switch Lighting uses a silicone-based liquid inside the

globe of its retrofi t lamps to cool the LEDs drawing heat to

the surface of the globe.

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Page 41: LED_Feb_2013

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40 FEBRUARY 2013 LEDsmagazine.com

luminaire design | WAVEGUIDES

MHA Lighting has developed a

unique LED approach that opens

up the use of solid-state lighting

(SSL) in new areas and applications which

competitors are failing to address with the

same level of effi ciency. Using patented intel-

lectual property (IP), MHA Lighting is the

only known LED lighting manufacturer to

shine light sideways into an encapsulation,

rather than directly outwards. Th is avoids

direct eye-contact of the light source, and

provides a safe and effi cient light output. Th e

fl exibility of its patented technology allows

MHA Lighting to replace fl uorescent fi ttings

and other conventional lighting technolo-

gies, in both indoor and outdoor applica-

tions, while meeting all relevant standards.

MHA uses a light-waveguide technology

in which the LED light is emitted sideways

into acrylic rods. Th is is achieved using spe-

cially-designed, linear, printed circuit boards

in which the sections containing the LEDs are

bent at 90˚ from the main sections. Th e PCBs

can be interlocked so that two LEDs on verti-

cal sections can sit back to back (Fig. 1).

The LED-containing extensions of the

PCBs are then inserted into matching holes

in an acrylic rod (Fig. 2). For obvious rea-

sons, MHA describes its technology as “Rods

with Holes.” Th e LEDs emit sideways into the

rod. Emission from the rod is controlled by a

refl ective coating which is designed accord-

ing to the desired light distribution. In this

way, light is emitted from the length of the

rod in a uniform manner.

Th e technology overcomes the problem of

directionality, and achieves a light distribu-

tion of such high uniformity that it is better

than traditional fi ttings. Luminaires create

a wide, rugby-ball shape of light to pro-

vide exceptional uniformity which for most

applications, both internal and external, is

crucially important.

Th e light-waveguide technology used by

MHA fi ts in with a growing industry trend of

maximizing “useful lumens,” where light is

directed effi ciently to specifi c locations. Th is is

in contrast to traditional light sources, which

are typically omnidirectional and wasteful.

Unique approach

MH A’s l ig ht-waveg uide technolog y

approach diff ers from technologies used

by other LED luminaire manufacturers,

which usually shine light directly out of the

fi xture or scatter the light through an opti-

cal diff user.

Direct emission: In this approach the

LEDs are usually arranged in a cluster or

matrix to shine their light directly out of

the fi tting. Th e earliest forms of LED-based

halogen-replacement downlights and fl u-

orescent-tube replacements utilized this

approach with mixed results. The light

MHA Lighting takes unique

approach to LED fi xture design with

Rods with Holes technology

A UK-based LED lighting manufacturer is using a unique light-waveguide approach in which LED

light is shone sideways into acrylic rods. In turn, these light-emitting rods provide a uniform light

distribution, explains TIM WHITAKER.

TIM WHITAKER is an Editorial Consultant with

LEDs Magazine.

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Page 43: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 41

output was limited and in many cases the

LEDs would overheat, or the individual light

sources were too bright, leaving an uncom-

fortable after-image for the viewer.

LEDs obscured by a diffuser: In this

approach, the LEDs are located behind a dif-

fuser so that the light source is masked from

the observer. In principle this approach pro-

duces the least amount of glare, as the LEDs

are hidden. However, the diff user introduces

losses to the system (reducing the effi ciency

by 20-30% or more). It also

inhibits control of the

beam direction, which

tends to be dominated by

the characteristics and

design of the diff user.

The MHA approach to

luminaires diff ers signif-

icantly from either of the

above methods. Th e tech-

nology relies on refl ecting

the light internally and

using the optical prop-

erties of the acrylic rod before the light is

emitted in a uniform manner.

The LEDs are arranged to shine their

light sideways within the optic so that

only a small proportion of the light is emit-

ted directly from the fi tting. Th e remain-

ing light waves are guided and then subse-

quently refl ected out.

Th is approach optimizes the

utilization of light from the

LED source and also allows for

an exceptionally good degree of

beam control and uniformity

of light. Th is minimizes light

wastage and light pollution.

Th e refl ector plays a crucial role in MHA’s

technology as it is Lambertian in its refl ec-

tance, meaning it is diff usely refl ective like

a matte object, as opposed to a mirror-like

refl ector that exhibits specular refl ection.

Th e optical waveguide effi ciency of MHA’s

Rod with Holes technology is very high and

has been evaluated extensively at the UK

National Physical Laboratory in Tedding-

ton, London. Optical effi ciency was found

to be in a range of 75-85% depending on

the specifi c system confi guration and the

required degree of directional beam control.

Th is effi ciency factor includes all the loss

factors associated with the light path from

the LED to the task plane. By comparison,

conventional diff user-based systems may

have effi ciencies as low as 50-60%, greatly

reducing the overall light output from the

fi tting. Light diff users also tend to inhibit

any kind of directional beam control, and

this may be an important consideration for

eff ective overall light deployment.

Th e design fl exibility inherent in this tech-

�FIG. 3. MHA Lighting’s

TiLite luminaires, with 80 CRI

and 4000K color temperature,

replaced T5 fl uorescent

fi ttings in Scott Safety’s UK

factory (www.ledsmagazine.

com/press/37007).

�FIG. 1. LEDs are mounted

on PCBs on sections that

are bent at 90° to the main

board. Pairs of LEDs are

inserted into matching holes

in acrylic rods.

FIG. 2. In MHA’s

“Rod with Holes”

technology, LED

light shines

sideways into acrylic

rods and is emitted

uniformly along the

length of the rod.

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Page 44: LED_Feb_2013

42 FEBRUARY 2013 LEDsmagazine.com

LED manufacturing | LARGE SUBSTRATES

nology facilitates secondary benefi ts when

used in specifi c tasks. For example, in street

lighting, it is possible to use lower mount-

ing heights, to reduce light pollution, reduce

glare and focus light on the task area.

Th e technology off ers a high degree of

light uniformity of which the beam angle

can be adjusted by a simple modifi cation of

the refl ector. Th is has the additional bene-

fi t in internal applications, where it is pos-

sible to direct light away from windows

and concentrate it in required areas or in

external applications, such as garage fore-

courts, where light can be refl ected inwards

to avoid light pollution.

Visual appearance

In tandem with the beam-control character-

istics, the Rod with Holes approach creates a

luminaire where light output is perceived as

emanating from a light strip or bar, rather

than from each individual LED. When indi-

vidual LEDs can be seen directly, very power-

ful after-images can be produced along with

eye discomfort and glare. Th e MHA approach

yields optimum lighting in an aesthetically-

pleasing manner, with fi ttings that are just as

pleasant to look at as a fl uorescent.

Th e high optical effi ciency of the MHA

waveguide system results in comparatively

high luminous efficacies (i.e. luminaire

lumen output per circuit watt), and thereby

a very good energy-saving performance

overall. Th is is true even against very effi -

cient fl uorescent lighting systems, such as

T5s. In addition to the energy savings there

is an accompanying saving in maintenance

costs as there is no need for maintenance for

a lighting system that is predicted to last as

long as 10-15 years. 

Th e Rod with Holes technology encour-

ages a luminaire design in which thermal

management can be achieved via a simple

passive heat-sinking method. Th e surface

area of the aluminum fi tting acts as the

heat-sink, and there is no need for active

thermal control or an excessively heavy

fi nned heat-sink, for example.

The MHA approach is unique in this

respect and can facilitate distinctive

designs with aesthetic appeal. Essen-

tially, MHA has a light engine that can be

adapted to suit any footprint, depending on

the application. Th e company rarely has to

carry out any new product development, as

the product range essentially uses variants

of the same light engine.

FIG. 4. LED light fi ttings consuming 67W from MHA Lighting have replaced 170W SON

fi ttings at Bournemouth Airport in the UK (www.ledsmagazine.com/products/37283).

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___________

Page 45: LED_Feb_2013

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Page 46: LED_Feb_2013

Welcome to a new era in smart connectivity – NECTOR power systems from TE Connectivity. NECTOR interconnects

give you the power to connect every fl oor of your intelligent building in smarter ways than ever before. Their compact

shape and smart design allow you to seamlessly integrate lighting, power and data throughout any retail, commercial

or offi ce environment. With the TE NECTOR product family, the possibilities are endless.

Watch the NECTOR video to see the future of power and luminaire design at NectorPower.com

EASY. FAST. COMPACT. (All this, and brains too.)

©2013 Tyco Electronics Corporation, All Rights Reserved. NECTOR, TE Connectivity and the TE connectivity (logo) are trademarks.

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Page 47: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 45

The American National Standard

Institute (ANSI) is currently devel-

oping a standard datasheet for white

LEDs used for general illumination, that can

in turn help the solid-state lighting (SSL)

industry overcome obstacles to broader

deployment. Datasheets are an important for-

mat for LED manufacturers to present prod-

uct information and characteristics to users.

Over the years, more and more LED man-

ufacturers have entered the general light-

ing market, and in almost all cases they use

datasheets to communicate with users and

assist them in selecting and implementing

LEDs in lamps, light engines or luminaires.

In the past, the information LEDs manufac-

turers have provided in these datasheets has

not been consistent, and as such, users have

expressed concern over lack of fair compari-

sons when selecting LEDs.

In the general lighting industry, most of

the components used in lighting products

have been standardized by ANSI such as

bulb shape, base, etc. Moreover ANSI has

defi ned all major characteristics, such as

voltage, wattage, etc.

LEDs for lighting applications, on the

other hand, are still rapidly evolving. At

least for now, ANSI has decided not to stan-

dardize LED package shape, footprint or

other physical parameters, which might

restrict further technology and product

development. Instead, the proposed ANSI

LED datasheet standard seeks to standard-

ize the information being communicated

between LED manufacturers and the rest

of the industry to ensure that fair and con-

sistent comparisons can be made by LED

users. In developing the ANSI LED data-

sheet standard, the ANSI Working Group

proposed: “The purpose is

to specify the standardized

white LED package data-

sheet, or data reporting for-

mat, as the means of com-

munication between LED

package producers and

users. Th e defi ned contents

and format of the datasheet

shall be followed.”

There are some who

argue the necessity of such

standardization. One con-

cern is that a standard-

ized datasheet may bury some liabilities

for the claims made by LED manufactur-

ers. Another concern is whether there are

suffi cient standards to be referenced when

obtaining or measuring the characteris-

tics and properties listed in the datasheet.

After extensive discussions, however, the

experts from participating LED manufac-

turers principally agreed that an ANSI stan-

dard datasheet can be a practical approach

which will benefi t the SSL industry. In addi-

tion, the establishment of some critical

standards for testing LEDs will be largely

helpful for LED manufacturers in consis-

tently obtaining the LED characteristics to

be listed in the datasheets.

Based on a broad view of datasheets cur-

rently published by major LED manufac-

turers and a general consensus from LED

industry experts, the con-

tents of the proposed ANSI

LED standard datasheet

are defined and grouped

into three areas: perfor-

mance and operational

characteristics; physical

and electrical connection

characteristics; and usage

recommendations. Th e stan-

dard also recommends that

the performance charac-

teristics be obtained by the

established (or to be estab-

lished) industry standards. For example, the

photometric and colorimetric characteris-

tics should be measured by IES LM-85 (to be

published); thermal characteristics should

be measured by JEDS51-51; and lumen and

color maintenance should be measured by

IES LM-80. Th e standard datasheet will also

list optional characteristics that LED manu-

facturers may want to, but do not necessar-

ily need to disclose.

In the performance characteristics area,

the standard datasheet fi rst addresses pho-

tometric performance. LED manufactur-

ers are required to provide information for

correlated color temperature (CCT) ver-

sus luminous f lux, color binning, lumi-

nous intensity distribution, luminous fl ux

changes versus forward current and ver-

sus temperature, color changes versus for-

ward current or versus temperature, and

luminous effi cacy versus forward current

ANSI works to standardize LED

datasheet for white LEDs

JIANZHONG JIAO reports that the ANSI standards body hopes to facilitate the communications of

pertinent component characteristics between LED manufacturers and SSL product developers.

DR. JIANZHONG JIAO, Director of Regulations and Emerging Technologies at OSRAM Opto

Semiconductors, Inc., is an internationally recognized lighting expert. He has been actively

involved in LED and SSL standard development activities. He serves as the past Chairman of the

SAE Lighting Committee, past Chairman of NGLIA, past Chairman of the NEMA SSL Technical

Committee, active member of IESNA Testing Procedure Committee, Roadway Lighting Committee,

and Computer Committee, ANSI SSL Working Groups, Standard Technical Panel of UL8750,

standard committees in IEEE, CIE USA, SEMI, JEDEC and other organizations. He can be reached

at [email protected]

standards | LED DATASHEETS

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Page 48: LED_Feb_2013

46 FEBRUARY 2013 LEDsmagazine.com

standards | LED DATASHEET

(as optional).

Some information is to be presented in a

table format, and other in a graphic format.

For example, for each listed CCT, whether

it is within, or in addition to ANSI C78.377

specifications, LEDs luminous f lux, CRI

values and corresponding product codes

are listed in a table format. Another exam-

ple is that the LED spectral power distribu-

tion (SPD) is provided in a graphic format.

Even though SPD may not be directly used

to design LED lamps or luminaires, it has

been widely acknowledged that LED users,

including lighting designers, fi nd value in

reviewing SPD information. Th e luminous

intensity in angular or spatial distribution

is also presented in the graphic format.

It is widely expected that LED lumen and

color maintenance information is needed

for designing SSL products. However, this

information can take over eight months of

LM-80 testing to become available. As such,

when new LEDs are launched for production

and the corresponding datasheets are pub-

lished, lumen maintenance test data is typ-

ically not yet available. Th us, the ANSI stan-

dard does not require lumen maintenance

information to be provided on the data-

sheet. LED manufacturers have the option

of providing this information if the previous

LM-80 data and TM-21 projection for lumen

maintenance of a similar LED product may

be used as a reference.

Because LEDs are temperature depen-

dent devices, thermal degrading is a criti-

cal design element. As such, all temperature

related characteristic changes will be listed

in the datasheet, often in a graphic format.

For the operational characteristics, the

datasheet will list operating limits, ther-

mal and electrical characteristics, forward

voltage versus forward current, forward

voltage binning, forward current versus

temperature, and forward voltage versus

temperature.

Next, the datasheet covers the physical

and electrical connection characteristics

including mechanical characteristics and

electrical diagram. It is required that the

LED’s physical properties, such as dimen-

sions, tolerances, locations of optical center,

anode and cathode, thermal pad, and elec-

trical connections, be shown in a graphic

format, so users can visualize the LED’s

physical appearance. Th e electrical diagram

that indicates external electrical connec-

tion points is also required and a diagram

of the internal diode is recommended. Th is

information helps users properly connect

LEDs to the overall electronic systems used

in LED lamps, light engines or luminaires.

Th e datasheet also describes the usage

recommendation. As the LED assembly

process can have an impact on overall per-

formance, a soldering temperature profi le

must be provided with the acceptable tem-

perature variation versus time for the LED

during the soldering process. Exceeding the

allowed temperature during soldering can

induce short term damage or a long term

impact on LED lumen maintenance.

LED packing information is also needed

for users to purchase LEDs. Th is informa-

tion may include mechanical diagrams

that show dimensions, number of LEDs

per package and packing format – if LEDs

are packed as tape and reel, tray, tube, or

another format. Optionally, the standard

also recommends LED manufacturers pro-

vide information for how the LEDs should

be handled, including equipment, ESD, etc.,

as well as what the environmental condi-

tions should be for storage.

The intent of the ANSI LED standard

datasheet is to ensure LED manufactur-

ers provide accurate, consistent and reli-

able product information, including the

order or sequence of that information. It is

not ANSI’s desire to put additional burdens

on LED manufacturers when establishing

standard datasheets and the ANSI Work-

ing Group is diligently working to achieve

the balance between benefi ts and burdens

of such standardization. All parties involved

hope that consistent communication – the

ANSI LED standard datasheet – between

LED manufacturers and users will be a valu-

able tool to further assist the growth of the

SSL industry.

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___________________________________

______________________

Page 49: LED_Feb_2013

Worldwide/Americas Headquarters • 109 Corporate Boulevard • South Plainfield, NJ 07080 • USA • +1-814-946-1611 – Dial 0 • www.alpha.alent.comEuropean Headquarters • Forsyth Road • Sheerwater • Woking GU215RZ • United Kingdom • +44-1483-758-400Asia-Pacific Headquarters • 8/F, Paul Y. Centre • 51 Hung To Road • Kwun Tong • Kowloon, Hong Kong • +852-3190-3100

© 2013 Alpha

alpha

®ledtec

The applications we address include:• LED die attach and chip-on-board (Level 1)• Package-on-board assembly (Level 2)• Luminaire board assembly and interconnect (Level 3)• Power driver and control system board assembly

(Levels 4 and 5)

Alpha offers the following products for LEDapplications:• ALPHA® Lumet™ Solder Paste with SAC

and MAXREL™ alloys• ALPHA® Cored Solder Wire• ALPHA® Exactalloy® MAXREL™ Solder Preforms• ALPHA® SACX Plus® Low Silver Bar Solder Alloy• ALPHA® Argomax™ Sintered Silver Products• ALPHA® Atrox™ Conductive Adhesives.

For more information go towww.alpha.alent.com/Markets/LEDOr, send an email [email protected].

Alpha’s LED materials technology bringsvalue to the LED Market by:• Increasing efficiency and brightness • Increasing reliability and lifetime • Reducing cost/lumen

hnologies

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Page 50: LED_Feb_2013

Produced &

Managed by

AMC, Inc.

In collaboration with

The Illuminating

Engineering Society

In collaboration with

The International

Association of

Lighting Designers

Philadelphia, PA USA

Pennsylvania Convention Center

4.21.13 – 4.25.13

THE FUTURE. ILLUMINATED.

2013

We see the future clearly. And so will you.

www.lightfair.com

PHOTO CREDITS

(1) BANNER MD ANDERSON CANCER CENTER LANTERN OF HOPE, GILBERT, AZ USA | LIGHTING DESIGN BY CANNON

DESIGN | © BILL TIMMERMAN / © MARK SKALNY (2) UNITED STATES INSTITUTE OF PEACE, WASHINGTON, DC USA |

LIGHTING DESIGN BY LAM PARTNERS | © GLENN HEINMILLER, IALD, LAM PARTNERS, © BILL FITZ-PATRICK, UNITED

STATES INSTITUTE OF PEACE (3) CHANDLER CITY HALL EXTERIOR LIGHTING, CHANDLER, AZ USA | LIGHTING DESIGN BY

SMITHGROUP JJR | © TIMMERMAN PHOTOGRAPHY

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Page 51: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 49

focu

s o

n SSL modulesA modular approach to LED-based luminaire design off ers a number of benefi ts to product manufacturers

including fast time to market, lower upfront engineering costs, and the ability to off er luminaires that can

be serviced or upgraded in the fi eld. Modular solid-state lighting (SSL) components enable custom luminaire

design based on combinations of off -the-shelf LED light engines, module holders/brackets, drivers, optics, and

other elements. Th e downside of modules can be less fl exibility in absolutely matching a luminaire design to

an application and slightly higher bill-of-materials cost relative to full custom designs. Still, modules off er

benefi ts that will clearly make the technology a lasting part of the ongoing transition of the lighting market

to SSL technology. Th e benefi ts of modular luminaire design (www.ledsmagazine.com/features/8/11/11) apply

in the product development process whether the components at hand are proprietary designs or based on an

evolving industry standard such as one of the Zhaga Books (www.ledsmagazine.com/features/9/7/15). Th is

compilation includes both proprietary modular products and ones built to the new Zhaga standards that allow

for interoperability of light engines, drivers, optics, and other components from multiple vendors.

Fortimo LED TDLM family by Philips

Th e Fortimo LED Twistable downlight module (TDLM)

is a simple to install and easy to maintain modular LED

light. Th is module is available in two color temperatures,

3000K and 4000K, includes a choice of

two holders, and has a CRI of

80.Th e family also includes

a number of different

lumen-output options,

such as a 1100-lm prod-

uct that’s compliant with

Zhaga Book 2: Socketable

downlight engine. The

term socketable, or twist-

able in the Philips prod-

uct name, implies that you can

mount the light engine into a bracket

without the use of tools. Philips also off ers a 2000-lm ver-

sion that at present isn’t Zhaga compliant.

LMH2 LED modules by Cree

Th e proprietary Cree LMH2 LED module family delivers 95

lm/W, has a CRI of 90, and comes in color temperatures

of 2700K, 3000K, 3500K, and 4000K. Th e module comes in

either a fl at lens or dome lens. Since the light source and

power supply are separate, the LMH2 can be mounted and

wired in a variety of diff erent confi gurations. Cree recently

established a Driver Compatibility Program that established

approved drivers for CREE SSL modules and the LMH2 mod-

ule family is initially the basis for the program (p. 21).

PrevaLED Core family by Osram

Th e PrevaLED Core family of light engines are compliant

with Zhaga Book 3: Round light emitting surface 9mm –

23mm that is targeted at spot

l ight applications and

requires separate con-

trol gear. PrevaLED

modules off er a CRI of

93. Th e modules fea-

ture chip-on-board

(COB) technology to

deliver uniform light

emission across the

surface. Th e family fea-

tures a number of products

with a variety of wattages from

10W to 31W, and color temperatures

that include 2700K, 3000K, 3500K, and 4000K. Th e highest

effi cacy in the family is 108 lm/W.

LED P3LED Recessed Series by Cooper

Th e Iris P3LED LED Recessed Series by Cooper is a Zhaga

book 3 compliant series of luminaires that feature inter-

changeable optics -- the fi rst luminaire that was certifi ed to

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Page 52: LED_Feb_2013

a Zhaga Book. Because Zha ga speci f icat ions

include thermal, electri- cal, mechanical, and optical

interfaces, luminaires must meet the specifi cations just

as light engines must. Th e series features a minimum CRI of 80, a

color temperature of 3000K, and are designed to last 50,000 hours.

Th e series includes a variety of recessed luminaires, including

downlights, accents, wall wash and lens products.

Infusion LED modules by GE Lighting

GE Lighting’s Infusion LED modules off er a large range of lumen

packages, which range from 850 lm to 4,500 lm. Th e modules are

designed for compatibility with Zhaga Book 5: Socketable engine

with separate gear, although the modules aren’t yet on Zhaga’s list

of certifi ed products. Th e series includes six modules, and uses a

twist-fi t installation/replacement method, allowing the entire mod-

ule to be removed in seconds. Th e series includes color temperature

options of 2700K, 3000K, and 4000K, with a CRI of 90.

XSM 80 series LED modules by Xiacto

Th e proprietary XSM 80 series

of LED modules by Xiacto

rely on remote- or cold-phos-

phor technology to provide

white light. Th e round mod-

ules combine blue LEDs with

secondary optics coated in

phosphor and Xicato says that

technology delivers superior

color quality. Th e spot-light series features LED lighting with a

color temperature range of 2700K, 3000K, 3500K, and 4000K, and a

CRI of 80. Th e effi cacy for each module is above 67 lm/W, with the

highest being 96 lm/W.

TECOH CFx by Megaman

Th e TECOH CFx twist-lock LED modules are designed in compliance

with the Zhaga Book 2 specifi cation. Th ese modules use a multi-

chip white LED array and feature a lambertian output. Because of

the twist-lock design, the light engines enable luminaires that can

be retained and upgraded as opposed to being replaced in the fi eld.

Th e modules feature a CRI of 80, and come in color temperatures

of 2800K or 4000K.

7100/d1/d2-GR light engine holders by A.A.G. Stucchi

These Zhaga Book 2 compliant holders by A.A.G. Stucchi are

designed to hold a Book 2-compliant modular light engine – a sock-

etable LED light engine with integrated electronic control gear.

Th e holder enables light engines to be installed and swapped out

if needed.

50 FEBRUARY 2013 LEDsmagazine.com

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Page 53: LED_Feb_2013

Z020C2 by Lustrous

Th e Z020C2 is a Zhaga Book 3 compliant spotlight module designed

for commercial lighting. Th ese modules have a CRI of 90, and are

meant to showcase products on the retail fl oor. Th e company was

the fi rst in the Asian region to win Zhaga certifi cation based on

testing by UL.

PHJ65d-1/d-2 light engine holders by BJB GmbH

Th e Zhaga Book 2-compliant holders work with LED light engines

with 100-VAC through 120-VAC power requirements. Th is holder

features a closed form to reduce the penetration of dust and dirt

into the luminaire.

Refl ex Easy by iGuzzini

Th e Refl ex Easy family of LED luminaires are modular recessed fi x-

tures that are designed to serve several diff erent applications. Th e

focus on | SSL MODULES

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Page 54: LED_Feb_2013

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Page 55: LED_Feb_2013

Light up your creative vision with Makrolon® Lumen XT

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Refl ex Easy family, which is Zhaga Book 2 compliant, includes a wall

washer luminaire, a circular spotlight, and a square design. Th e lumi-

naires come with a variety of wattages for applications as well, from

14W to 44W.

Helieon by Molex

Description: Th e proprietary Helieon family of LED modules from

Molex (developed in partnership with Bridgelux) features a wide vari-

ety of products, with varying beam angles, base types, lumen outputs,

CRI’s that are all 80 or above, and color temperatures of 2700K, 3000K,

3500K, and 4100K. Th e versatile family is designed to serve across a

wide variety of applications.

LMR2 LED modules by Cree

The proprietary Cree LMR2 LED

module family features a CRI of

90, color temperatures of 2700K,

3000K, 3500K, and 4000K, and

comes with integrated driver

electronics, optics, and core

thermals. The modules also

include an optional heat sink

and support dimming down to

5%. Th e modules are designed for

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Page 56: LED_Feb_2013

54 FEBRUARY 2013 LEDsmagazine.com

applications in non-directional lighting, directional lighting, down-

lighting, or exterior area lighting.

SynJet ZFlow 87 Spot LED Cooler by Nuventix

Zhaga Books defi ne a thermal interface to a light engine as well

as electrical, optical, and mechanical interfaces, and Nuventix has

designed a number of its SynJet-based, active-cooling devices for

Zhaga-based luminaire designs. Th e ZFlow 87 Spotlight LED cooler

is 87-mm in diameter and designed for use with Book 3 light engines.

Th e 47W thermal-load version is pictured. Moreover the ZFlow 75

34W version is used in the Cooper Lighting P3LED luminaire.

FORTIMO LED SLM 3000 family by Philips

Th e Fortimo LED Spotlight Module (SLM) 3000 family is designed

to illuminate merchandise and attract customers in a retail envi-

ronment. Th e family features lamps and drivers with a high CRI

and tight color consistency. Th e products include COB LED tech-

nology, which helps the system off er performance of more than

100 lm/W. Th e family is compliant with Zhaga Book 3 for spot-

light applications.

XLM 80 Series LED modules by Xiacto

Th e XLM 80 series of linear rectangular modules by Xiacto target

linear lighting applications. Like the XSM 80 series, the products use

remote-phosphor technology. Family members deliver 3000-4000

lm and range in color temperature from 3000K to 4000K. Th e main-

stream products have a CRI of 80, although the specialty Artist

series comes with a CRI of 90.

S-Class street lighting module by Carclo

Modular light engines comes in many form factors

– driven in part by application – and this

new S-Class module from Carclo is

designed specifi cally for street-

lighting applications.

Carclo is an optics

specialists and

this is the compa-

ny's first complete

light-engine off ering.

The S-Class is a pro-

prietary design but still

includes the thermal, opti-

cal, and electronic elements that

can accelerate the luminaire devel-

opment cycle. Carclo views the entry

into the light-engine business in part as a way to provide custom-

ers easier access to its optics.

SynJet ZFlow 65 Cooler and CoolTwist Heatsink by Nuventix

The SynJet ZFlow 65 Cooler and

CoolTwist Heatsink is designed

for Book 2 applications and

light engines such as the

Philips Lighting Fortimo

TDLM module target-

ing downlights. Nuventix

off ers the product in a range

of sizes with the capability of

handling thermal loads as high as 48W. Th e 40W unit pictured is

95-mm in diameter and generates less than 28 dBA in acoustic noise.

EdiLex Spot Light Module by Edison-Opto

With the EdiLex Spot Light Module (SLM) Edison-Opto turned

to a COB LED array that it says provides a uniform plane of light

across the light emitting surface. Th e design uses the company’s

focus on | SSL MODULES

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Page 57: LED_Feb_2013

Simply Brilliant!NEW Programmable LED Drivers from NMB

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EdiPower II components that come

in versions ranging from 8-25W. Th at

enables Edison-Opto to offer light

engines that output 800, 2000, and 3000

lm. Th e company says that the product

supports spot- and fl ood-light applica-

tions via refl ectors that if off ers in 25°, 35°,

and 60° beam widths.

Linear TALEXXengine Stark LLE by Tridonic

Tridonic off ers light engines in a variety of form factors including

the TALEXXengine Stark Linear Light Engine (LLE) family that

comes in rectangular and even square confi gurations (the QLE).

Th e modules off er effi cacy as high as 118 lm/W – 108 lm/W includ-

ing a Tridonic driver. Th e newest linear module measures 24 mm

(0.95 in) by 280 mm (11 in) for applications such as ceiling troff ers.

Tridonic off ers the products in 3000K, 4000K, and 5000K CCTs.

Cetero SLM by Bridgelux

Bridgelux took advantage of its ES

series of LED arrays to design

the Cetero Spot Light Module

(SLM) that is compatible with

Zhaga Book 3. Th e company

is off ering the light engine

in 800-, 1100-, and 2000-

lm packages. The mod-

ule comes in a choice of

2700K, 3000K, 3500K, and

4000K color temperatures

and a CRI of 80. Moreover,

Bridgelu x specif ies color

consistency within a 3-step

MacAdam ellipse.

focus on | SSL MODULES

E

i

e

e

lm

sup

tions

and 60°

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...

Page 58: LED_Feb_2013

CALL FOR PAPERS! DEADLINE: 22 FEBRUARY 2013

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Page 59: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 57

technology | COLOR SCIENCE

Much of the technical focus on LEDs

and solid-state lighting (SSL) to

date has been on component and

system effi cacy and the potential for saving

energy, but lighting quality matters as well.

In this part of our color-science series, we

will see how high effi cacy and

good color rendering are con-

f licting goals. Moreover, we

will address how the industry

is attacking the problem of

developing effi cient and high-

quality light sources.

In the first article of this

series we established three

foundational principles of

color vision: 1) The relative

response of the three types

of cone cells in the retina is

sufficient to explain color

vision; 2) metamerism which

is a direct result of the first

principle; and 3) color can be

characterized by numerous

sets of color-matching func-

tions, all of which are linear

transformations of each other

(w w w.ledsmagazine.com/

features/9/5/4).

In the second article we used these prin-

ciples to explain the origins and uses of

the CIE Color Diagram including predict-

ing the color coordinates in the CIE Color

Diagram for mixtures of colors (www.leds-

magazine.com/features/9/7/14). We also dis-

cussed the origins of the Planckian locus, a

curve through the center of the CIE Diagram

which plots the color coordinates of a par-

ticular type of white light sources known as

blackbody radiators. In the third article in

the series we built upon this knowledge to

show how to design LED-based illumina-

tion devices which mix the light from diff er-

ent color temperature white LEDs and from

colored LEDs to achieve results not possi-

ble with white LEDs of the same color tem-

perature alone (www.ledsmagazine.com/

features/9/10/15).

In this article we will look at color ren-

dering properties of white LEDs. Color ren-

dering refers to how the color appearance of

illuminated objects can change when illu-

minated by diff erent light sources. Natu-

rally we expect colors to shift somewhat

when illuminated by light sources with dif-

ferent correlated color temperatures (CCT).

We are aware of the change in colors of

objects outdoors from noon to sunset on a

sunny day. You may have even had the expe-

rience of choosing a paint color at the store

under natural or fl uorescent lighting and

then being disappointed in the color of that

paint as it appears on your

walls at home under incan-

descent lighting. Both of

these examples of color ren-

dering are within our com-

mon experience, are to be

expected, and in part can be

explained by diff erent CCTs of

the light sources.

What is less apparent,

though, is that the color of

an illuminated object can

change significantly when

shifting from one illumina-

tion source to another, even

when both sources have the

exact same CCT and even

when they have the exact

same chromaticity coordi-

nates. To understand how

this can happen, let’s review

and apply our fi rst two prin-

ciples of color vision.

Our fi rst principle of color vision states

that the colors we see are directly related

to the relative response of the three types

of cone cells in the retina to the spectral

power distribution (SPD) of the light falling

on the cone cells. Th is means that two light

sources with widely divergent SPDs can

nonetheless still result in the same relative

response of the three types of cone cells and

hence look like the exact same color. Th is is

also why a mixture of the light from a red,

a green and a blue LED can have the same

Understand color science to maximize

success with LEDs – part 4

Color rendering, or how color appears when illuminated by a light source, is crucial in the

performance of SSL systems, explains GEORGE KELLY, and in the fourth part of our series on color

science we will cover how LED and SSL architecture impacts lit objects.

GEORGE KELLY is an LED Technical Specialist

at Avnet Electronics Marketing.

FIG. 1. The SPD of the light emitted by the bulb is modifi ed by the

spectral refl ectance of the pigment of the light blue balloon forming

a new SPD that enters the eye.

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_________

__________

______

__________________

Page 60: LED_Feb_2013

0.9

1.0

400 450

Fluorescent

Incandescent

LED

500 550 600 650 700 750

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0

Wavelength (nm)

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

400 450 500 550 600 650 700 750

Wavelength (nm)

TCS01

TSC02

TCS03

TCS04

TCS05

TCS06

TCS07

TCS08

TCS09

58 FEBRUARY 2013 LEDsmagazine.com

technology | COLOR SCIENCE

FIG. 2. SPDs of 3000K fl uorescent and Incandescent

lights compared with a white LED.

color as a 3000K incandescent lamp, even

though the SPDs of the lamp and the LED

mixture are vastly diff erent. As long as the

cone responses to the two SPDs are identi-

cal, then the two sources will look identical

in color. Th is phenomenon is called metam-

erism, and is our second principle of color

vision. Any two or more SPDs that have the

same chromaticity coordinates are metam-

ers of each other.

Refl ected light

The situation changes when we view

refl ected light from two or more metameric

light sources. In this case, the spectral con-

tent of the light coming from each source is

modifi ed by the spectral refl ectance prop-

erties of the object the light is refl ecting off

of before it enters our eyes. A blue object for

instance refl ects at the blue end of the spec-

trum, roughly 400-500 nm, and absorbs the

medium to long wavelengths. Consequently,

the SPD of the refl ected light now is a func-

tion of both the SPD of the source and the

spectral refl ectance properties of the illu-

minated object (Fig. 1).

This complex interaction means that

the color of an object can shift dramati-

cally when illuminated in succession by

two metameric light sources. Even though

the two light sources have the exact same

chromaticity coordinates, if their SPDs

diff er then the SPDs of the refl ected light

will also differ. Moreover, the SPDs of

the refl ected light will most likely not be

metamers of each other and consequently

will appear to shift in color at least slightly

if not dramatically.

Color rendering is of particular impor-

tance for indoor LED lighting. Th e SPD of a

typical white LED is very diff erent from that

of typical indoor lights whether incandes-

cent or fl uorescent (Fig. 2). Consumers may

be disappointed to fi nd that the colors of

familiar objects in their home or offi ce will

change signifi cantly when they install new

LED light bulbs.

Th e lighting industry has faced this prob-

lem in the past and devel-

oped the color render-

ing index (CRI) metric to

quantify the color render-

ing properties of a partic-

ular light source compared

to that of an incandescent

source for low color tem-

peratures (< 5000K) and to

daylight for high color tem-

peratures (> 5000K). If the

match is perfect, meaning

that colors appear or ren-

der the same under the

light source in question as

they do under daylight or

an incandescent source,

then the index will be an

even 100. CRI is not perfect as a predictor of

the color rendering performance of a light

source, but it does do a reasonable job.

CRI is calculated by comparing the chro-

maticity coordinates of a set of standard

patches or color swatches when illuminated

by the light source you are testing and by a

reference light source. Th ese

standard patches have spe-

cific spectral ref lectance

distributions, meaning the

percent refl ectance at each

wavelength for each patch

is specifi ed. Specifying the

chromaticity coordinates

of the patch is meaning-

less without specifying a

light source illuminating

the patch or more precisely

specifying the source’s SPD.

CRI uses fourteen patches

in all. Eight are used to

derive the actual CRI value

(see sidebar – Calculating CRI) and the

additional six provide individual measures

for specifi c colors of interest. Th e patches

were chosen to be representative of com-

mon materials (Fig. 3).

The importance of CRI in SSL

CRI is primarily important for indoor light-

ing and is less important for outdoor light-

ing. High-pressure sodium (HPS) street

lights for instance, have a very low CRI, in

some cases as low as 20. Th is poor color ren-

dering is off set by exceptional luminous

effi cacy, which can be as high as 150 lm/W.

Color rendering in this application is gen-

erally considered unimportant when com-

pared to energy effi ciency. Some HPS lamps

do have slightly higher CRIs, but at the sac-

rifi ce of lower luminous effi cacy.

The only outdoor lighting application

where high CRI is important is architectural

lighting, such as wall washers and fl oodlights

used to illuminate façades and landscapes. A

low CRI in an architectural application can

signifi cantly detract from the aesthetics of an

illuminated building or landscape.

In indoor lighting, CRI is particularly

important in residential, retail, and restau-

rant lighting. Color rendering in offi ce envi-

ronments is of less importance, because

offi ce lighting is designed to provide the best

lighting for performing tasks and less so for

aesthetics.

LED-based retrofi t lamps and to a lesser

extent SSL fi xtures are starting to make

inroads into the residential lighting market.

For this market penetration to continue, the

cost of the LED lamps and fi xtures must

continue to come down, while the quality

remains high. Th e higher cost of LED light-

ing products compared to CFLs and incan-

descent bulbs can be off set to some degree

by the long lifetime of LEDs and by the con-

FIG. 3. The spectral refl ectance of the eight color

swatches used in the calculation of CRI plus the strong

red used to calculate R9.

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Page 61: LED_Feb_2013

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

360 410 460 510 560 610 660 710 760

Wavelength (nm)

Phosphor

Blue LED

Photopic

curve

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

400 450 500 550 600 650 700 750

Wavelength (nm)

Photopic

curve

0

0.1

0.2

0.3

0.4

0.5

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0.7

0.8

0.9

1

400 450 500 550 600 650 700 750 800

Wavelength (nm)

Photopic

curve

LEDsmagazine.com FEBRUARY 2013 59

technology | COLOR SCIENCE

tinuing increases in LED energy effi -

ciency. Th e quality of LED products

though involves more than just reli-

ability. Th e quality of the light pro-

duced by an SSL lamp or fi xture is

also important, especially to resi-

dential customers. The quality of

light in SSL is essentially the color

rendering quality of the LEDs them-

selves. Since CRI is our only objec-

tive standard to quantify color ren-

dering, it becomes an important

product specification along with

reliability and luminous effi cacy.

Achieving high CRI with LEDs

LED manufacturers often face com-

peting goals, such as cost and per-

formance. Manufacturing high CRI

LEDs with high luminous effi cacy

especially for warm color tempera-

tures is one such challenge. Th e rea-

son for this has to do with how white

LEDs actually create white light.

White LEDs are actually blue

LEDs coated with a phosphor mate-

rial. Th e phosphor absorbs a portion

of the blue light from the LED with

the rest passing through the phos-

phor. Some of this light absorbed by

the phosphor excites electrons in

the phosphor molecules to a higher

energy level. As these electrons fall

back to lower energy states they emit

photons. Th e spectrum of the light

emitted by the phosphor is broad-

band in nature ranging from 500-

700 nm with a peak typically around

550 nm.

If the phosphor were to absorb all

of the blue light it would glow yellow.

Since it doesn’t absorb all of the light

from the blue LED, the transmitted

blue light and the yellow light emit-

ted by the phosphor combine to cre-

ate what appears to be white light.

If the mixture has more blue light

than white, it will be a cool white

with a high CCT. If the mixture has more yel-

low light from the phosphor than blue light

from the LED, it will be warm white with a

lower CCT.

Effi ciency and effi cacy

The optical performance of this LED

architecture is rather effi cient for two rea-

sons. First, blue InGaN LEDs are very effi -

cient at turning the electrical power sup-

plied to them into optical power. The

luminous effi ciency of an LED is defi ned as

the optical power in radiant watts of the

light exiting the LED divided by the input

electrical power in watts. For a typ-

ical blue InGaN LED, the effi ciency

is 30-35%. Despite this high effi-

ciency, blue LEDs have very poor

luminous effi cacy because the eye

is not very sensitive at blue wave-

lengths. Indeed eye sensitivity is

what drives the use of effi cacy mea-

sured in lumens per watt as the pri-

mary figure of merit rather than

effi ciency. Th e emission spectrum

of the phosphor, however, lines up

well with the eye spectral response

curve, V(λ) and consequently most

of the luminous effi cacy of a white

LED is due to the yellow light emit-

ted by the phosphor and very little

due to the blue light passing through

the phosphor (Fig. 4).

In fact if we weren’t concerned

with color rendering or having the

chromaticity coordinates of the LED

fall close to the Planckian curve, we

could make a super high luminous

efficacy LED by using a phosphor

whose emission spectra matches the

V(λ) curve as closely as possible and

then making the phosphor layer thick

enough so that all of the blue light

from the blue LED was absorbed by

the phosphor.

While matching the SPD of an

LED to the V(λ) curve as closely as

possible will make a very effi cient

and therefore bright light, it will not

make white light. For that, we need

some light on the blue and red ends

of the spectrum even if the light at

those wavelengths contribute little

to brightness perceived by the eye.

For cool white LEDs this is rather

easy to do, by simply letting enough

of the blue light from the LED leak

through the phosphor.

For warm white LEDs, the phos-

phor must have enough power at the

red end of the spectrum to create the

warm white CCT. For a 2700K LED,

phosphors with a broad emission spectrum

are chosen that have a peak emission in the

590-630-nm range. Unfortunately these

phosphors also generate a great deal of light

beyond 650 nm where the eye has very lit-

tle response, contributing little to the lumi-

nous effi cacy of the LED. Th is is why LEDs

FIG. 4. SPDs of the blue light and phosphor of a typical

4500K white LED with a CRI of 80, overlaid on the

Photopic Curve.

FIG. 5. SPD of Osram's Brilliant Mix delivering a CCT of

2700K and CRI of 92 overlaid on the Photopic Curve.

FIG. 6. SPD of a dual-phosphor White LED delivering a

CCT of 2700K and CRI of 94 overlaid on the Photopic

Curve.

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Page 62: LED_Feb_2013

60 FEBRUARY 2013 LEDsmagazine.com

technology | COLOR SCIENCE

with a lower CCT also have a lower luminous effi cacy than the cooler

color temperature LEDs in the same family.

High CRI, warm CCT

Th e situation is worse when we want to have a high CRI, low color tem-

perature LED – a combination desirable in residential applications. In

this case we need even more long wavelength light (600–700 nm) rela-

tive to medium and short wavelengths. To accomplish this, the peak of

the phosphor has to shift farther towards the red end of the spectrum,

further lowering the luminous effi cacy of the LED.

SSL manufacturers have off ered two solutions to this problem. One

solution is to add a red LED to a white LED to boost the red content

of the spectrum without compromising the effi cacy of the white LED.

Brilliant Mix by Osram is one example of this. Brilliant Mix actually

improves the total system effi cacy by using a greenish-white LED with

a phosphor that matches the V(λ) curve closely, consequently maximiz-

ing luminous effi cacy (Fig. 5).

Th e second approach uses a two phosphor system. Th e main phos-

phor is shifted towards the blue end of the spectrum and then a second

phosphor with a narrower bandwidth and a peak around 610-620 nm is

added to boost the red end of the spectrum. Th is second phosphor adds

the required power at the red end of the spectrum without wasting too

much power at wavelengths above 650 nm (Fig. 6).

Th e fi rst approach can produce CRIs above 90 for 2700-3000K LEDs and

still maintain high luminous effi cacy. Th e second approach can achieve CRIs

above 95, but with lower luminous effi cacy than lower CRI white LEDs.

Beyond CRI

CRI as a color rendering metric has several known defi ciencies. Th e

most obvious is that it uses only eight spectral refl ectance distributions

(swatches) to represent the infi nite number of possible spectral refl ec-

tance distributions of real objects that can be encountered in real appli-

cations. Several replacements for CRI have been proposed such as the

color quality scale (CQS) by Davis and Ohno at NIST (www.ledsmaga-

zine.com/news/7/5/29). Until CQS or another metric becomes the new

color rendering standard, we are left with CRI.

Th e six additional swatches included in the CRI standard can be used

to some degree to make up for the small number of spectral refl ectance

distributions used in the standard. Th e R9 value which is a saturated red

is often of interest for white LEDs since white LEDs often do not render

deep reds well due to a shortage of light at long wavelengths. Compar-

ing the R9 values of two LEDs in addition to comparing their CRI values

can be instructive, especially for applications where the color render-

ing of red is important.

Th ere are also applications where a CRI approaching 100 may not be

desirable. Th is may even be the case in residential, retail and restaurant

lighting where high CRI is assumed to be essential.

For instance, in some situations you may want LED lighting that

increases the saturation of colors. CRI does not discriminate between

color rendering shifts that make colors appear more desaturated or more

saturated. All color diff erences between the test and reference sources

are treated equally. It is well known that in digital photography we prefer

photos with more saturated colors. It is rather standard practice today

to increase the color saturation of digital photos using image process-

ing software.

Calculating CRI

The CRI of a light source is calculated by comparing

the chromaticity coordinates of eight standard patches

or color swatches when illuminated by the light source

in question (the test source) and by a reference light

source. The test patches are not actually illuminated

by either the test or the reference source. Instead the

chromaticity coordinates of the light that would be

refl ected off of each patch by each sources is calculated

by multiplying the SPDs of each source by the spectral

refl ectance distributions of each patch. The spectral

refl ectance distributions of the eight patches were

chosen to be representative of common materials. The

metric used to quantify the color differences under the

test and reference light sources is the Euclidean distance

in the CIE 1964 color space,ΔΕCIEUVW , with chromaticity

coordinates, U′, V′, and W′. An additional six patches

are also tested individually and reported separately,

providing supplemental color rendering information for

those colors.

The steps in calculating the CRI of a source from its

SPD are as follows:

• Determine the CCT of the test source.

• Generate the SPD of the reference source.

• If the CCT of the test source is less than 5000K then

use the SPD of a blackbody radiator with the same

CCT as the test source.

• If the CCT of the test source is greater than 5000K,

use the SPD standard illuminant D with the same

CCT as the test source.

• Calculate the SPD of the refl ected light for each

of the eight spectral refl ectance distributions of

the color swatches for both the test and reference

sources. This is done by multiplying the SPD of each

source by the spectral refl ectance of each swatch on

a wavelength by wavelength basis.

• Find the x, y chromaticity coordinates of the refl ected

light and then convert to U′, V′, and W′ chromaticity

coordinates of the CIE 1964 color standard.

• Apply a “von Kriess transform” to the U′, V′, and W′

values to account for chromatic adaptation by the

human visual system.

• Calculate the ΔΕі= ΔΕCIEUVW color differences

between the test and reference sources for each

color patc h.

• Calculate the specifi c color rendering index for each

patch by, Rі = 100 - 4.6ΔΕі

• Average the eight Ri values to arrive at Ra, which is

the CRI value for the test source. ◀

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technology | COLOR SCIENCE

Increasing color saturation

Th is fact suggests that we may pre-

fer lighting that increases color sat-

uration. By enhancing the amount

of light at key wavelengths in the

sources’ SPDs, we could increase the

color saturation or chroma of spe-

cifi c colors and in the process reduce

the CRI. With LEDs, this is easy to

imagine. If we wanted to enhance

the primary colors we could mix in

additional red, green and blue light

from red, green and blue LEDs along

with a typical white LED (Fig. 7).

In the example in Fig. 7, red, green

and blue LEDs are added to the

warm white LED depicted in Fig. 6,

resulting in a 5500K CCT with a CRI

of 81. Although the CRI drops signifi cantly

it does so because the saturation of the color

swatches in the CRI calculation increases

with the exception of swatches TCS02 (yel-

low) and TCS06 (light blue). Th e saturation

of both of these swatches remains largely

unchanged. Th ese results only apply to the

particular swatches use in the CRI calcu-

lations. It is practically impossible to pre-

dict how swatches with diff erent spectral-

ref lectance characteristics would render

when illuminated by such a light.

Similarly, it may be possible to alter

the SPD of LED lights in such a way

to enhance the appearance of specifi c

items such as food in restaurants and

in grocery stores. LED technology

gives us the tools for the fi rst time to

tailor the SPD of light sources at least

to some degree. How this fl exibility is

used in new applications over the next

few years will be exciting to watch.

The tradeoff between CRI and

luminous effi cacy is currently a major

focus in the industry. As LED lumi-

nous effi cacies continue to improve,

LEDs will enjoy an even greater com-

petitive advantage over competing

technologies such as CFLs. At that

point the marginal return of further

increasing LED luminous effi cacy will make

trading some of that effi ciency off for higher

CRI a more attractive option. Phosphor tech-

nology should also continue to improve,

reducing the need to tradeoff luminous effi -

cacy for higher CRI.

FIG. 7. Adding a red LED (640 nm), a green LED (525

nm) and a blue LED (460 nm) to the white LED shown

in Fig. 6 results in a 5500K light with a CRI of 81. Reds

and greens and purples will appear more saturated

under this light than under the light in Fig 6.

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Page 65: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 63

2 in

8 in4 in

6 in

LED manufacturing | LARGE SUBSTRATES

In the search to cut the costs of manufac-

turing LEDs, switching to large diam-

eter (6-8-in, 150-200-mm) substrates is

often brought up as a key solution. In fact,

it is mentioned so often that one might

assume a mass transition to large diameter

has already occurred. Such a transition has

been slow to happen due to both technical

and logistical challenges. But as we will dis-

cuss, the advantages will ultimately be sig-

nifi cant enough that the LED manufactur-

ers will move to larger substrates, reduce

component costs, and further accelerate the

adoption of solid-state lighting (SSL).

Analysts are predicting that for 2013, less

than 20% of production will be on 6-in wafers,

with 8-in not even showing up in signifi cant

numbers this year. Even three years from now,

large diameter is only predicted to be break-

ing the halfway point of all substrate sizes.

Th is may come as a surprise because the

demand for large diameter should be very

high – it has often been cited as a fundamen-

tal cost saver to drive down LED chip prices.

With the industry-wide search to drive down

cost signifi cantly, and large diameter seen

as a key way to accomplish this, why aren’t

more chip producers making this switch?

To answer this question, we will look at

three areas. First, what are the true bene-

fi ts of large diameter? Second, if the benefi ts

are truly great, then why aren’t more man-

ufacturers switching? Finally, we’ll look at

some of the potential disruptions that might

bring quicker large diameter adoption, such

as c-axis CHES (controlled heat extraction

system) technology – along with the pros-

pect of 8-inch substrates.

More LED chips

We’ll begin by looking at the main advan-

tage of moving to larger wafers – more LED

chips. Yes, this is the biggest advantage, but

it’s also unfortunately often overstated in

this way: a large diameter 6-in wafer has

nine times more surface area than a 2-in

wafer on which to form LED chips (Fig. 1).

While the prior statement is certainly true

in regards to the simple surface area of the

wafers, the suggestion that you get 9× more

chip throughput by simply using 6-in wafers

sounds too good to be true – and it is. What’s

the real story? In order to answer that, we

need to look closely at the layout of LED chips,

both on the wafer and as a group of wafers in

the MOCVD (metal organic chemical vapor

deposition) reactor where LEDs are formed.

In addition to 6- or 8-in wafers simply

being larger, we have to consider several other

factors to get a true picture of the benefi t of

“more LED chips.” Th ese factors are exclusion

zone, LED chip shape and size, and MOCVD

reactor layout. We’ll explain these one at a

time, then feed them into a true comparison

simulator that will give us a much more rea-

sonable look at the number of LED chips sup-

ported by various wafer sizes.

Exclusion zone

We will fi rst look at what’s called the exclu-

sion zone on a wafer. During epitaxy, LED

material is not properly formed in this area,

meaning these chips shouldn’t

be counted because they will

not result in good LEDs. For

our LED chip calculator, we

are using an industry stan-

dard 3-mm exclusion zone,

which is shown as red chips

in Fig. 2. Note that the chips

on the extreme edge of the

wafer – that are actually hang-

ing off the wafer if they were

full rectangles – are not going

to be counted at all for our

simulation.

One important characteris-

tic of the exclusion zone is that

it is 3-mm from the edge regardless of wafer

diameter. This fact means that the large

diameter wafers have larger exclusion zone

areas. However, as a percentage of the total

wafer surface area, the large wafers have a

smaller proportion of their area in exclu-

sion zones.

So you can see how a 6-in wafer that has

9× more gross surface area actually has more

than 9× more net area (gross area minus

exclusion zone). Th e advantage results in

6-in wafers having 10.3× more net area, and

8-in wafers having 18.8× more, both as com-

pared to a 2-in wafer.

We also have to account for the rectangu-

Manufacturing LEDs on large diameter

substrates: What’s the holdup?

A transition to 6- or 8-in wafers will ultimately deliver lower-cost LEDs, although as MARCUS WEDDLE

discusses, the industry must overcome technical and logistical challenges.

MARCUS WEDDLE is Marketing Manager for ARC Energy, based in Nashua, New Hampshire. Th e

company manufacturers CHES sapphire crystal growth furnaces and processing systems for the

LED, SOS, and optical/commercial industrial markets.

FIG. 1. Small- and large-diameter sapphire cores.

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Page 66: LED_Feb_2013

64 FEBRUARY 2013 LEDsmagazine.com

Exclusion zone

(Black ring)

2 in 4 in 6 in 8 in

Gross surface area

advantage over 50 mm - 4× 9× 16×

Net surface area

advantage over 50 mm - 4.4× 10.3× 18.8×

Net LED chip count

advantage over 50 mm - 4.6× 10.9× 19.8×

3-mm exclusion zone edge

Chips counted in exclusion zone

Chips not counted

LED manufacturing | LARGE SUBSTRATES

lar footprint of LEDs. Th ey don’t perfectly

fi t in the round shape of the wafer – some

LEDs will be lost by partially crossing into

the exclusion zone. In a similar way to the

exclusion zone, these losses are a higher

percentage of the total for the smaller

wafers. The final advantage is shown in

the chart in Fig. 3 that is based on 45x45-

mil (thousandths of an inch) LEDs, includ-

ing the spaces between chips. Th e result is

slightly higher gains in chip count com-

pared with area – 10.9× for the 6-in and

19.8× for the 8-in wafers.

MOCVD reactor layout

At this point, we’ve seen that a 6-in-diameter

wafer actually holds slightly more than the

often-quoted 9× more LED chips compared

to a 2-in wafer. But now we have to consider

that LEDs are grown in groups of wafers in

an MOCVD reactor.

Th e LED epitaxy process is one of the most

expensive and time consuming of all the

steps that go into the fi nal delivery of an SSL

product. Th e input is a group of wafers, and

the output is thousands of LEDs on those

wafers. What we are seeking to answer is

how switching to large diameter will change

that LED count after the epitaxy process. Of

course, yield – a measure of chips that func-

tion correctly – matters too, but we will look

at that later.

We’ve already said that you shouldn’t

expect the chip count you get after epitaxy

to jump by a factor of nine, and now we’ll

see why. Th e primary reason is the fact that

so many more small-diameter wafers can fi t

in the reactor chamber. In a typical MOCVD

reactor confi guration, 56 2-in wafers can be

loaded. In the same reactor only eight 6-in

wafers will fi t. Th at’s a ratio of 7:1 in favor of

small diameter.

So to simply break even in the fi nal count,

each 6-in wafer would need to hold 7× more

LED chips than a single 2-in wafer. How-

ever, we’ve already seen that a 6-in wafer

has almost 11× more

LED chips. Put in other

terms, the 6-in config-

uration results in 55%

more LED chips (1.55×).

This is the final true

advantage we’ve been

looking for. While this

is much less than the

9× (900%) figure that

we started with, it is

still a very significant

improvement in the

number of LED chips

you get for the same

cost of time and money

for an MOCVD run. You

can compare a typical MOCVD layout for

small and large diameter wafers and their

respective chip counts in Fig. 4.

LED chip size

We do need to consider another factor, and

that is LED chip size. For our calculations

we’ve used 45×45-mil rectangles, includ-

ing the street width, or spaces between the

chips. Th is size – around one square mil-

limeter – is typical for high-brightness

LEDs and is therefore a good comparison.

However, as chip sizes increase the advan-

tage for large diameter wafers also increases

slightly. For example, if you use a 60×60-mil

rectangle, the advantage

for 6-in wafers increases

to 58%.

So fa r we have

focused on comparing

2-in to 6-in wafers, but

we should discuss other

sizes as well. Today’s

LEDs are also made on

3- and 4-in wafers in

large numbers. What

is the relationship with

these other sizes? Mov-

ing from 2-in to 4-in

only gives 14.7% advan-

tage, using a standard layout of 14 4-in

wafers in the reactor. Th e gain from 4-in to

6-in is much more signifi cant at 35.2%.

For 8-in substrates, the advantage is a

very large – 77% more LED chips over 2-in –

and that is only from the fi ve 8-in wafers that

can fi t in a typical MOCVD reactor. Compar-

ing a move from 6-inch to 8-in directly, there

is a 14% gain.

We now have an accurate view of the

advantage large diameter brings to the LED

chip count: 55% more for 6-in and 77% for

8-in. While these are impressive numbers,

one factor we haven’t taken into account in

our LED chip simulation is LED chip yield.

We will look at this important factor next.

Higher yield

Each step in the manufacturing process of

an LED chip has a yield loss, from the prepa-

ration of substrates through chip packaging.

Th e yield losses at each step add up and con-

tribute to a signifi cant portion of the fi nal

chip cost. Th ere is therefore a great deal of

focus currently on improving yield in all of

these areas.

Switching to large-diameter LED manu-

facturing has been linked to yield improve-

ment in a number of stages of the manufac-

turing process. Th e potential benefi ts come

both directly as the larger wafer size is a

more uniform surface for epitaxy and indi-

rectly through the use of better manufactur-

ing equipment and techniques. While yield

can be a complex subject, we will briefl y look

at some highlights of the possible benefi ts.

One of direct yield benefits of larger

wafers comes during epitaxy. In the MOCVD

chamber, any physical disturbances, such

as wafer edges, can disturb the gas fl ow and

FIG. 3. Larger wafers greatly increase the number of LED

chips produced per wafer.

FIG. 2. LED chips in the exclusion zones along the edge of

wafers are not usable.

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Page 67: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 65

200 mm

5 pockets

150 mm

8 pockets

50 mm

56 pockets

Overlay of 150 mm

showing surface

area advantage

Small diameter Large diameter

56×50 mm (2") 8×150 mm (6") 5×200 mm (8")

Net surface area 88,274 mm2 130,288 mm2 147,796 mm2

Surface area gain

vs. 50 mm - 48% 67%

Count of 45×45 mil

LED chips 62,944 97,600 111,280

LED chip count gain

vs. 50 mm - 55% 77%

150 mm cores

Defects in the core result

lost wafers (red area)

Coring with defects cannot

be avoided with large diameter

c-axis

coring

a-axis

growth

Older technology

a-axis boule

Defect losses reduce utilizationto less than 20%

LED manufacturing | LARGE SUBSTRATES

FIG. 5. Taking large sapphire cores from a-axis boules

results in signifi cant material losses and more defects.

reduce yield. Larger wafers

can help here because there

are fewer edges and more

undisturbed surface area.

Th e resulting higher yield

during this expensive step

is an important advantage.

Th e second component of

improved yield comes from

access to modern process

control and automation

tools, which are designed

around large-diameter

wafers and have been per-

fected in IC manufactur-

ing. Today’s commonly

used small-diameter man-

ufacturing techniques use

manual processes, requir-

ing many human interac-

tions, and lack sophisti-

cated tracking that could spot yield issues.

Many experts have pointed to a general

need to move from a research-style produc-

tion environment to a true mass production

environment. Let’s look in a little more detail

at what this means.

Automation primarily refers to the use of

machines to handle and transport wafers –

removing the human element. Wafers can be

moved faster and with less damage through

automated machines instead of being hand

carried. Th e benefi t is a combination of fewer

skilled operators required, less loss of wafers

due to mishandling, and quicker movement

through the manufacturing steps.

In addition to more automation, the use

of more modern tools brings better process

control. Process control is the use of data

analysis to detect and predict problems

that cause yield losses in any area of the

production process. Th is involves a track-

ing and analysis of the substrate through-

out the process, extending back to the crys-

tal growth stage. Process control also takes

into account the analysis data recorded by

the various production tools.

Th e use of process control is often cited

as a necessary step in advancing the LED

industry. As with automation, the tools

needed for implementing process control are

designed around large-diameter substrates,

so the benefi t to switching goes beyond just

more LED chips. For additional informa-

tion on the industry’s move to improve yield

through large-diameter wafer production,

see the article “LED wafer and automation

standards are on the fast track, ready for

more industry feedback” (www.ledsmaga-

zine.com/features/8/10/9).

Market conditions

At this point, we’ve seen how switching to

large diameter wafers can create more chips

per MOCVD run and improve yield in sev-

eral areas. Yet the industry

this year is still predicted to

produce over 80% of the LED

capacity using small-diame-

ter substrates. Why? Th e rea-

sons come from two factors:

difficult market conditions

and technological challenges

in supplying large diameter

substrates at a competitive

cost.

Th e price of 2-, 3-, and 4-in

wafers has dropped dramat-

ically in the past two years

due to an oversupply condi-

tion and lower-than-expected

demand. At the same time, a

step in the manufacturing

process called PSS (patterned

sapphire substrate) has

increased the performance of LEDs. Th ese

two factors made staying with small diam-

eter an attractive option while waiting for

higher demand. However, some large compa-

nies moved ahead despite these conditions

and are today prepared for a rapid increase

in production as demand grows.

Technology barriers

Th e second barrier to the adoption of large

diameter substrates is a group of techno-

logical hurdles. It begins with challenges in

sapphire crystal growth – the fi rst step in

creating substrates. As you can see in Fig.

5, today’s sapphire for HB-LEDs is typically

grown on the a-axis, even though HB-LEDs

require c-axis wafers. To get c-axis wafers

from a-axis sapphire boules, a core must be

taken sideways – wasting a large part of the

sapphire.

Today’s a-axis sapphire growth tech-

nologies also result in defects that cannot

be avoided when coring for large diameter

applications. Th e volume of a 6- or 8-in core

is so large that the defects become unavoid-

able and the cores must be shortened or

scrapped. Th e total losses from sideways cor-

ing and defects waste over 80% of the mate-

rial. For 8-in applications, the waste is over

90% and the production costs double.

Another barrier caused by a-axis growth

is that the resulting wafers have a varia-

tion in stress and strain across their sur-

face. Because the wafer is from a sideways

core of the boule, and the boule is grown

along the a-axis, the wafer itself has a long

growth time signature across its surface.

Th is becomes signifi cant during epitaxial

growth when the wafer is heated.

FIG. 4. The number of wafers that fi t in an MOCVD reactor

ultimately gates the advantage of larger wafers.

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66 FEBRUARY 2013 LEDsmagazine.com

75+% material

utilization

CHES c-axis

growth direction

and coring

CHES

c-axis boule

2D cross-section

side view

Wafer heated during epitaxy:

3D view

Variation

in stress

and strain

during

growth

Older technology

a-axis boule

Wafers cored using

older technologies

have a long growth

time signature and

variations in stress

and strain

LED manufacturing | LARGE SUBSTRATES

FIG. 6. Wafers from a-axis boules are subject to warp

during the MOCVD process.

As you can see in the Fig. 6, the wafer will

bow in an uneven pattern or a warp. Th is

warping is very diffi cult to counteract by

the MOCVD engineer and has caused several

attempted workarounds, including a move

to thicker wafers and the use of stress-reliev-

ing layers. Th ese techniques add to the pro-

duction cost and complexity. Without coun-

teracting the warp, the result during epitaxy

is lower LED chip yield.

Th e last technology barrier is in the slic-

ing and polishing of the wafer and applica-

tion of PSS techniques. Slicing and polish-

ing are diffi cult processes and must be done

well to generate good yield during epitaxy.

Because the large wafers are 9-16× larger, the

diffi culty increases signifi cantly.

PSS application faces a similar challenge,

with the additional obstacle that the pattern

can only be seamlessly applied to a limited

size area smaller than 6 in. In order to get

PSS on a 6-in wafer, a stepper (a semiconduc-

tor manufacturing tool) must apply multi-

ple patterns, which is common in the silicon

industry. However, for HB-LEDs the edges of

the multiple pattern applications must be

closely matched or LED yield will drop. Th is

accuracy requirement is proving to be very

challenging.

Th ese barriers of market conditions and

technology challenges have created multiple

limitations for the mass adoption of large-

diameter substrates. In the future, the mar-

ket demand will require the throughput and

yield only available using larger substrates,

and as a result the technology challenges

will be overcome. As proof of the possibil-

ity of overcoming the challenges, several

tier-1 manufacturers have already made the

switch and are positioned with an advantage

over the majority of the industry.

Potential substrate disruptions

It is certain that HB-LED manufactur-

ing will ultimately move to large-diame-

ter substrates. Th e question is how quickly,

and what material will be used for the sub-

strates? In this last section we’ll briefl y look

at potential answers to these questions.

As we said at the beginning, adoption

of large-diameter is currently low and pre-

dicted to take years to complete. However,

advances in alternative substrates to tradi-

tional sapphire may accelerate this adoption

or carve out niche channels for some compa-

nies. But fi rst we’ll focus on sapphire.

Th e main challenges we noted were the

low material utilization due to a-axis growth

and the high level of defects that make larger

wafers expensive. There are alternative

growth technologies that can grow directly

on the c-axis for much lower waste. In addi-

tion, growth technologies that avoid signif-

icant defects are also available.

Sapphire grown with these characteristics

of c-axis growth (also called on-axis growth

for LED applications) and low defect levels

are very well optimized for large-diameter

applications. As you can see in Fig. 7 depict-

ing c-axis CHES technology, the problems of

low material utilization and high defect lev-

els are both solved at once, with the addi-

tional benefi t of a near net shape boule. Th e

result is over 75% utilization for both 6- and

8-in applications.

In addition, the problems of warp during

epitaxy that we saw from a-axis-grown sap-

phire are reduced as the c-axis CHES wafers

are grown with a single time signature across

their surface (Fig. 8). Because of these advan-

tages, it is expected that as more manufac-

turers move to large-diameter applications,

the growth technologies will also transition

to c-axis, low-defect-level growth.

Alternative substrates to sapphire, such

as silicon, silicon carbide, and gallium

nitride (GaN) are also being researched.

A small number of LED

manufacturers are even

in production on each of

these substrates, yet not

as a cost-effective alter-

native to sapphire. Each of

these alternatives has cer-

tain advantages over sap-

phire, yet multiple break-

throughs are needed for

one of them to signifi-

cantly displace sapphire.

Of the alternative sub-

strates, current predic-

tions give silicon the best

chance for success.

Because LEDs have

such a broad potential

market, there will be

room for these alternative

substrates along with sap-

phire remaining predom-

inant. For example, an

advantage GaN substrate brings is higher

performance per chip – albeit at very high

cost. Th is substrate may fi nd a niche where a

single bright LED chip is desired or required.

The next diameter past 6-in is the 8-in

wafer. Th ese wafers give another dramatic

gain in LED chip count and further opportu-

nities for yield improvement. Yet the barriers

we examined earlier are the same, with the

addition of the sapphire substrate costs dou-

bling over 6-in using a-axis growth methods.

Th erefore the prediction is that one of these

FIG. 7. C-axis sapphire boules improve

material utilization and minimize defects.

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Page 69: LED_Feb_2013

CHES c-axis

growth and coring

CHES c-axis waferOlder technology

a-axis wafer

With c-axis growth, wafers exhibit

less bow and warp during epitaxy

2D cross-section

side view

3D view

No stress and strain due to

a single time signature of growth

LED manufacturing | LARGE SUBSTRATES

alternative technologies (sapphire grown

on c-axis, silicon, or another substrate) will

become dominant for 8-in wafers and beyond.

Obstacles and benefi ts

In summary, we found a move to large-diam-

eter-based LED manufacturing provides a

55% increase in LED chips per MOCVD

run using 6-in wafers, and a 77% using 8-in

wafers. In addition to more chips, the yield

would increase throughout the manufactur-

ing process due to better epitaxy yield, auto-

mation, and process control.

The reason these advantages haven’t

become common except with the largest

LED manufacturers are several market and

technology barriers. Th ese include a-axis

sapphire growth technology, a depressed

market, and the use of PSS. But new c-axis-

growth technology provides an optimized

path to supplying large-diameter sapphire

substrates. Other substrate materials, such

as silicon, will likely fi nd niche uses with

some manufacturers. Th e advances of larger

wafers will continue to the next step of 8-in.

Large diameter has already been proven

by large tier-1 manufacturers as an impor-

tant component in reducing costs and

increasing performance of HB-LEDs. See

“Philips Lumileds announces workhorse

Luxeon T LED family” (www.ledsmagazine.

com/news/9/12/7) for an example.

Yet many companies are staying with

small diameter wafers until the next

demand wave comes. However, companies

that are planning ahead to gain a competi-

tive edge – as is possible with large-diameter

LED manufacturing – will be more effi cient,

more fl exible to meet demand, and fi nd suc-

cess in the future.

FIG. 8. C-axis wafers exhibit less strain and warping during epitaxy.

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_____________

Page 70: LED_Feb_2013

Thomas Research ProductsSSL Solutions Faster Than The Speed Of Light

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Page 71: LED_Feb_2013

LEDsmagazine.com FEBRUARY 2013 69

fi nancing | SSL PROJECTS

Lighting can represent a significant

proportion of energy consumed in

non-domestic buildings, typically

accounting for 20% to 55% of the total elec-

tricity consumption on a commercial site.

Each year in the UK, non-domestic lighting

is responsible for around 24 million tonnes

of CO2 emissions according to the Carbon

Trust. Improving the energy effi ciency of

lighting can therefore yield signifi cant cost

savings, while reducing the environmental

impact. By deploying effi cient lamp tech-

nologies such as LEDs, CFLs and energy-

saving halogen lighting, cost reductions of

up to 80% are possible compared with tra-

ditional lamp technology. Intelligent light-

ing controls can be used to further reduce

energy consumption, usually between 30%

and 50% in a typical offi ce environment.

Clearly, there is a compelling case for

moving to more energy-efficient lighting

systems both from the fi nancial and envi-

ronmental perspectives. Nevertheless, many

companies are hesitant to take the fi rst step,

largely because they are reluctant to spend

their capital reserves or simply lack access

to aff ordable funding. According to the Bank

of England, the annual rate of growth in the

stock of lending to UK businesses was nega-

tive in the three months to August. Th e stock

of lending to small and medium enterprises

(SMEs) and large businesses also contracted

over this period.

Boosting green investment appetite

To help businesses make green investments

in a tight credit environment, the Carbon

Trust and Siemens Financial Services

Limited (SFS) have initiated the Energy

Efficiency Financing scheme (EEF). The

scheme is designed to provide fi nancing for

organizations acquiring energy-efficient

equipment, with aff ordable monthly pay-

ments designed to match – and to be off set

by – the average monthly savings on energy

bills. In some cases, the value of the energy

savings can be greater than the monthly

fi nance payments, allowing the end cus-

tomer to be cash-fl ow positive from day one.

Suppliers of energy-effi cient equipment

can also apply to become a

recognized supplier of the

scheme, which in turn will

allow them to integrate the

financing offer into their

overall sales propositions.

Th is removes the obstacle

of large up-front capital

investment for customers,

and helps suppliers to close

more deals as eff orts can be

focused on providing the

best solution, rather than

being constrained by busi-

nesses facing capital budget restrictions.

In addition, fast payment of invoices for

the energy-effi cient equipment are made by

SFS to recognized suppliers directly – usu-

ally within a day of receipt of correctly com-

pleted documentation – meaning improved

cash fl ow for the suppliers.

How the EEF scheme works

Financing can start from as little as

GBP1000 and go up to as much as hundreds

of thousands of pounds, even millions. Each

application (which must be from companies

with at least three years of trading history)

is assessed on its own merits and monthly

payments are adjusted to match or be less

than a customer’s anticipated energy cost

savings. Th is is usually arranged over terms

between one and seven years, although in

selected cases this can be for longer periods.

Where possible, the scheme wraps every-

thing into a single fi nancing package under

a loan, lease or hire-purchase arrangement.

Th is includes the cost of an energy-effi ciency

assessment, the equipment itself and instal-

lation. Customers can also include other

aspects, such as service into their monthly

payments, as well as nego-

tiating upgrades and add-

ons in the future as their

needs change. Financing

can be arranged directly by

the customer with SFS or

through the scheme’s rec-

ognized suppliers.

Prior to fi nancing being

approved, normal checks

for credit acceptance will be

conducted and an energy-

saving assessment will be

undertaken by experienced

specialists at the Carbon Trust, giving busi-

nesses the assurance that the expected car-

bon reduction, and fi nancial savings over

time, will match or exceed the finance

payments.

Reaping fi nancial gains with EEF

Th e EEF scheme has already helped many

organizations reap financial savings and

reduce their carbon footprint. Nailcote Hall,

a hotel situated in Solihull, Warwickshire, has

leveraged this specialist fi nancing to work on

a re-lamping project, converting 670 regular

halogen light fi ttings (which use between

35-100W) into LED light fi ttings using only

7W of power. Th e GBP30,000 ($ 48,000) invest-

ment should bring a saving of approximately

Energy Effi ciency Financing scheme

lights up the path to green savings

A UK-based fi nancing scheme provides funds to cover the upfront cost of lighting equipment, with

repayments aligned with energy-bill savings, as DARREN RIVA explains.

DARREN RIVA is the Head of Financing for the

Energy Effi ciency Financing (EEF) scheme.

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Page 72: LED_Feb_2013

G R E E N L I G H T I N G L E D

A New Idea in Thermal Conductivity

GKN has developed new heat sink materials to improve

thermal conductivity by as

much as 50% over traditional

materials. Our innovative

process, utilizing recycled alu-

minum and green technology

allows for greater design free-

dom vs. conventional stamped

and extruded products.

THINK �Aluminum Powder Metal. THINK GKN.

GKN is the world’s largest producer of precision powder

metal products. With a focus on superior delivery, quality

and total solutions, the company offers extensive tech-

nical expertise in design, testing and various process

technologies. GKN Sinter Metals provides a wide range

of products for engines, transmissions, drivetrains, and

interiors for both the automotive and industrial markets.

Tel: 828-466-6771 Web: www.gknsintermetals.com

fi nancing | SSL PROJECTS

PRODUCT showcase TO PROMOTE YOUR PRODUCT HERE, PLEASE CONTACT BOB COLLOPUY

AT bobc@pennwell .com, JOANNA HOOK AT joannah@pennwell .com

OR ALLISON O'CONNOR AT [email protected]

70 FEBRUARY 2013 LEDsmagazine.com

GBP12,000-14,000 a year, with a return on

investment (ROI) of around two and a half

years. As the monthly payments are less than

the monthly energy savings achieved from the

new lighting, the hotel is cash-fl ow positive

from the very start of the project.

Th e North East Convenience Stores, a com-

pany with 18 outlets located from Blyth in

Northumberland to Eston in Middlesbrough,

has invested approximately GBP50,000 to

upgrade one of its premises with fi nancing

from the EEF scheme. By replacing all refrig-

eration units and chillers with an energy-effi -

cient, remote open-deck refrigeration system,

and at the same time replacing the existing

lighting with LEDs, the electricity bill has

been cut by 40% and payback is expected in

less than two and a half years.

Paving the way for the green journey

With the esta blishment of the EEF scheme,

a large capital outlay is no longer a pre-req-

uisite for green investments by businesses.

Organizations can now easily afford to

upgrade their lighting as well as other equip-

ment to more energy-effi cient alternatives,

thereby cutting unnecessary overhead and

strengthening their competitive position.

For equipment suppliers – such as light-

ing manufacturers – who can off er technical

expertise as well as a fi nancing option such

as the EEF scheme in their sales proposition,

the commercial advantage they have over

their peers will no doubt benefi t their busi-

ness and help make the green journey a much

smoother experience for their customers.

LINKS

Next Generation Streetlights guide covers LED technology to fi nancing www.ledsmagazine.com/news/9/12/13

Europe provides funds and updates legislation to stimulate growth in SSL www.ledsmagazine.com/features/9/9/3

DOE Consortium introduces fi nancial tool for LED street lights www.ledsmagazine.com/news/9/2/12

Bridgelux and Chevron partner on LED street lights, announce California installations www.ledsmagazine.com/news/9/3/1

European Commission initiates public consultation on LED lighting www.ledsmagazine.com/features/9/2/2

Appalachian launches smart LED street light and SSL Energy Solutions fi nancing www.ledsmagazine.com/news/8/10/6

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__________

Page 73: LED_Feb_2013

V E R D E D E S I G N S

VERAWATT™ VW(D)-100-4-25-CC

Utilizing the power

of today’s micro-

controllers,

Verde Designs®

has invented a

driver that can

future-proof

your LED fixture

with the click of a

button. VERAWATT™ LED drivers are software program-

mable via the Programming Interface Tool (PIT). The

VERAWATT™ series of LED drivers are unique in that

they can be configured for virtually any dimming solu-

tion as well as the ability to dial in any current or voltage

value that your product requires. Available in both AC-DC

and DC-DC technologies, VERAWATT™ lets you use the

same driver, so your LEDs can change but your drive

stays the same.

Tel: 480-256-0000

Email: [email protected]

Web: www.verde-designs.com

Report highlights:Comprehensive overview of the LED downlights market, including geographical distribution, sales channel, market drivers, and residential vs. commercial applications.

Review of the LED downlights market and a 5-year industry forecast.

Learn more about this report & view the table of contents online at www.strategies-u.com or contact:

Tim Carli, [email protected], +1 650 946 3163

New Report Available Now!

LED Downlights:Market Analysis and Forecast 2012

ROA L E L E C T RO N I C S U S A I N C .

MESO Programmable LED Drivers

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designed for fast, easy con-

figuration. Create hundreds of

configurations from 6W to 25W

from just a few SKUs. External

analog and DALI programming

tools permit customization

of key parameters, allow-

ing designers to easily personalize drivers for discreet

final products without the need for extensive inventory.

Reduces design time, inventory risk and leadtimes!

AC or DC Input

Analog or Digital Control

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Email: [email protected]

Web: www.roallivingenergy.com

Visit us at

Strategies in Light

Booth #804

KO N I C A M I N O LTA S E N S I N G

Konica Minolta Sensing’s CL-500A

Illuminance Spectrophotometer

Konica Minolta’s instruments are recognized for the high-

est quality and performance, reliability, innovative design,

and ease of use. The compact

and lightweight CL-500A

Illuminance Spectrophotometer

is a first of its kind. This all-in-

one instrument is traceable to

NIST and can easily measure

color temperature, CRI, indi-

vidual R values including R9,

and display the spectral power

distribution directly on the unit. You can read the measure-

ment data using the included Excel add-in software. Data

Management Software CL-S10w can be used to control up

to 10 CL-500A units for multi-point measurements.

Visit us at Booth #717 at Strategies in Light

for more information

Tel: Toll Free (888) 473-2656

Email: [email protected]

Web: sensing.konicaminolta.us

LEDsmagazine.com FEBRUARY 2013 71

PRODUCT showcase

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________________

Page 74: LED_Feb_2013

72 FEBRUARY 2012 LEDsmagazine.com

Startup

cell

BL

HV VCC

CVCC

CBulk

RSense

GND

FB

CS

Gate

Converter

DC output85 – 270 VAC

Control unit

PWM controller

current mode

Snubber

Precise low tolerance

peak current limitation

Active burst mode

Latch off mode

Auto restart mode

ICE3BS03LJ (Latch & jitter)

Power

management

While several IC suppliers today

off er dedicated switching ICs

designed specifically for LED

applications, the majority of these devices

do not support DC-bus output voltage lev-

els greater than 45V, with a few devices

using advanced process technology that

support up to 60V. Th e output-voltage lim-

its the number of LEDs that can be driven

in a series confi guration where current

is shared equally among each LED in the

string. Th e limit to LEDs in a string can

both limit the total lumen output of a solid-

state lighting (SSL) design or the ability to

implement a color mixing scheme – espe-

cially given that white LEDs have larger

forward voltage (Vf) values than red LEDs.

Driver developers, however, can use fi xed-

frequency and quasi-resonant (QR) fl yback

controllers to implement the DC-DC con-

version stage and support higher DC volt-

ages and more LEDs.

Color mixing is one of several cases

when the need to support output voltage in

excess of 60V may be desirable. For exam-

ple, a 72V output can accommodate a string

of 19 white/blue/green LEDs or 24 red LEDs.

Alternatively, a manufacturer may need to

accommodate a wider range of DC bus volt-

ages derived from the converted AC line.

For example, consider the need to accom-

modate universal AC input voltages (85V-

270V) for use in a product sold globally.

Let’s examine power-stage designs that

can accommodate comparatively high DC

bus voltage values. We will discuss a QR

controller with minimal turn on losses and

subsequent low electromagnetic interfer-

ence (EMI). And we will discuss both fi xed-

frequency and QR controller designs with

an added transistor to support dimming.

SPICE (Simulated Program with Integrated

Circuit Emphasis) simulation results will

demonstrate each concept and extract the

basic features of the QR controller, includ-

ing valley switching and current limit, to

prove the concept.

Typical applications for f lyback con-

trollers are in transformer-isolated AC-DC

applications. These devices also possess

features that allow them to be utilized

effectively in DC-DC buck, or step-down,

applications where supply voltages for

accommodating larger strings of LED’s

(50V and higher) are necessary. Addition-

ally these controllers can be configured

to support other useful features includ-

ing dimming and programmable current

capability.

Fixed-frequency and QR controllers

Both the fi xed frequency and QR controllers

(Figs. 1 and 2) contain an embedded power

cell or start-up cell capable of working with

high input-voltage values. Before the AC line

voltage is fully applied and has stabilized,

these internal cells provide a stable supply

voltage to the IC so it can perform the neces-

sary regulation. Th is is achieved by an inter-

nal switch that charges up the capacitor on

the VCC terminals before the stabilization

of the line voltage.

Once the line voltage stabilizes, the start-

up cell becomes inactive unless power is

interrupted. Under normal AC line condi-

tions the IC derives its VCC power from a

rectifi ed AC source voltage. For either con-

troller, voltages in excess of 270V can be

supported at the IC input. Th is supported

input voltage value is far greater than that

supported by the typical DC-DC, fi xed-fre-

quency switching regulators that exist today

for LEDs. As previously noted, most are only

capable of handling maximum supply volt-

Fixed-frequency and

quasi-resonant fl yback controllers

drive large LED strings

FRED SAWYER and MLADEN IVANKOVIC explain how to drive large LED strings, including RGB

implementations, for high-lumen-output applications.

FRED SAWYER is a Senior Staff Field

Applications Engineer, and MLADEN

IVANKOVIC is a Senior Application Engineer

at Infi neon Technologies.

design forum | DRIVING STRINGS

FIG. 1. Fixed-frequency fl yback controller.

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Page 75: LED_Feb_2013

CBus

CVCC

CZC

CFB

Dr1~Dr4

Power

cell

FB

GND

HV VCC ZC

RZC2 RZC1

RVCC DVCC

RCS

Rb1

Optocoupler

Rb2 Rovs1

Rovs2

Rc1

TL431

CDS

Cc1 Cc2

CS

Q1

Gate

85 – 265 VAC

Control

unitZero crossing detection

Power management

Digital process block

Active burst mode

Protection block

Current mode controlICE2QS03

Current

limitation

Gate

driver

WpWs

Do Vo

Co

Cf

Wa

LfSnubber

LEDsmagazine.com FEBRUARY 2013 73

ages of 60V (and more typically 45V).

A simple buck converter uses a fi xed fre-

quency controller that supports a DC input.

Th e driver acts as a constant current source,

so that regardless of the number of LEDs

connected each diode will see the same cur-

rent value. Th e transistor provides the refer-

ence voltage for the feedback and is matched

with the current-sense resistor in order to

achieve the desired output regulation.

Using the fi xed frequency device is a quick

and easy way to implement the DC-DC buck

converter concept. Its drawback is that as

a fi xed switching frequency device it exhib-

its greater EMI than other available alter-

natives. Moreover the maximum supported

duty cycle for these controller devices is

between 80-85%. Th is means that the out-

put voltage for the LED supply can only be

80-85% of the input voltage. As an example

a 60V DC input bus would be limited to sup-

porting a 48V DC output and 12-15 LED’s.

Quasi resonant advantages

For designs having stricter EMI standards

and needing tighter diff erentials between

the input and output voltage bus values, a

QR device should be employed. Th e exam-

ple in Fig. 2 uses Infi neon’s ICE2QS03, which

contains an integrated start up cell along

with a digital frequency-reduction feature.

QR operation minimizes EMI by turning on

the fi eld-eff ect transistor (FET) at the out-

put during the zero crossing phase – a tech-

nique commonly known as valley switch-

ing. Another eff ect of turning on the FET at

the zero crossing phase is reduced turn on

losses, making this a very effi cient switching

solution for a DC-DC buck converter applica-

tion. We shall see in a subsequent example

how this solution also accommodates dim-

ming applications.

Zero-voltage-switching operation occurs

when there is a resonant condition result-

ing from inductor L1 and the FET output

capacitance in the fully off state. Under

this condition, capacitor voltage eventu-

ally begins to fall and the inductor current

goes to zero.

We simulated this circuit concept using

National Instruments Multisim SPICE soft-

ware package. Th e inductor current and

FET drain waveforms are shown in Fig 3.

In this example the input voltage is 100V.

Th e output voltage and Inductor L1 con-

trol the rise and fall time of the current.

Th e turn on of the FET is initiated at the

valley point once the FET drain to source

voltage has been detected to reach its max-

imum value (100V). During this condition

the FET is deemed off and is subsequently

switched on by the QR controller. During

this phase the inductor current rises and

once the peak is reached the FET is fully

on. At this point the FET is turned off and

the inductor current discharges. Th e FET is

fully off once the inductor current reaches

zero and the drain to source reaches 100V.

Circuit performance

Fig. 4 illustrates the total average power

(voltage×current) across the switching cycle

and demonstrates how the QR controller

concept minimizes losses during turn on.

FIG. 2. Quasi resonant controller.

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________________________

Page 76: LED_Feb_2013

0-25

0

25

50

75

100

125

10 20

Time (μs)

Transient analysis

Voltage (V)

Current (A)

30 40

00

100

200

300

400

500

600

10

Turn on losses

are minimized

20

Time (μs)

Transient analysis

Voltage × current

305 15 25

74 FEBRUARY 2013 LEDsmagazine.com

design forum | DRIVING STRINGS

We performed average power simulations

on this circuit design to determine the effi -

ciency characteristics of this QR concept.

While simulation represents only a the-

oretical result of what is to be expected

it nonetheless provides a good starting

point for evaluating this concept. The

analysis was conducted assuming ideal

components (capacitors and inductors),

so the designer can view the losses that

are strictly attributed to the application

of the QR topology.

K e y f i g u re s f rom t he a n a ly si s

include an average output power of

(96.4579+96.4551)/2= 96.45W and an aver-

age input power of (99.5510+97.3866)/2=

98.46. If you divide the output by the input

we calculate converter effi ciency of approx-

imately 98%. As noted, this fi gure does not

take into account the eff ect from non-ideal

components and or imperfections in the

circuit-board layout.

Dimming and current programming

In our circuit design, dimming can be

implemented by applying a pulse-width

modulation (PWM) input to the feedback

(FB) pin and replacing the FB resistor with

a photo bipolar junction transistor (BJT)

placed in parallel with a current mirror

transistor such as the BC846. When the

paralleled confi guration of the transistors

is turned on, the FB pin is grounded and

there is zero current.

Turning the transistors off sets the maxi-

mum current condition for the LED string.

Th us by applying a PWM input, the resis-

tance seen by the FB

pin can be changed,

which adjusts the

current f low and

establishes the dim-

ming properties.

As previously men-

tioned, the ICE2QS03

QR controller has a

d ig it a l-f requenc y-

reduction property.

Once l ighter load

c ond it ion s e x i st ,

such as during the

dimming of the LED

light engine, the con-

troller subsequently

reduces its switch-

ing frequency in accordance with the load.

This positively impacts – reduces – the

switching losses that are associated with

the FET and the inductor under

light load. Th us the controller

operates at optimal effi ciency

for any load condition.

Likewise the photo BJT, when

connected in parallel with the

BC846, can be used to program

the current characteristics for

the driver via PWM control.

Th e PWM scheme provides an

effective bias mechanism to

the transistors giving them the

properties of a variable resistor

which in turn can control the

current levels.

Added safety features

A further modifi cation to the

FIG. 3. The waveforms depict the QR-switching or valley-switching concept. The yellow

trace is the inductor current and the red trace represents the FET drain voltage.

FIG. 4. A Multisim analysis shows the average power

(voltage×current) over the switching cycle.

QR switching in the ICE2QS03

A review of the functions performed by the

ICE2QS03 and each of the IC pins help illustrate

the overall operational concepts discussed in

the main article.

The zero current (ZC) pin takes in the

voltage resulting from the oscillation dictated

by the inductor and FET parasitic capacitance.

Internally, this pin is connected to the zero-

crossing detector for to determine the switch-on

time of the FET for resonant operation.

The current sense (CS) pin is connected to

the shunt resistor for primary current sensing

externally, and to the PWM signal generator

to in part determine the switch-off time for

the FET. The controller ultimately uses the

CS function and the voltage present at the

feedback (FB) pin to determine when to switch

the FET off.

The circuit operates by looking at the

sensed voltage across the shunt resistor (CS)

and the voltage is applied to an internal current

measurement unit integrated inside the IC. The

output voltage from the CS pin is compared

with the regulation voltage that is represented

by the FB input. Once this current sense

voltage exceeds the FB voltage, the output fl ip-

fl op inside the IC is reset. As a result, the FET is

switched off. ◀

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Page 77: LED_Feb_2013

LED1L1

LED2

MOSFET

LED3 LED6 LED4 LED5

R4

R2

HV

Q1

BC846

R1C1

0F

R3

Current

sense input

OutTLE4305

Overvoltage

protection

ZC

FB

CS

Gate

GND

VCCICE2QSO3

HV

LEDsmagazine.com FEBRUARY 2013 75

design forum | DRIVING STRINGS

FIG. 5. The addition of circuit-protection features can allow the controller to survive a

fault in the LED string.

QR design introduces detection and protec-

tion circuitry, so that a break in the LED

string does not create an overvoltage con-

dition. Th is is illustrated in the block dia-

gram in Fig. 5.

Th is design adds the TLE4305, which is

a combination voltage and current regu-

lator for switch-mode power supplies. Th is

device is used in conjunction with the QR

controller to provide the internal reference

voltage needed for the current sense. It is an

extremely low internal reference voltage (200

mV) thereby facilitating the use of smaller

current sense resistors in the application.

The QR controller has a zero-crossing-

detection (ZC) pin which performs multiple-

functions. First in addition to performing

the switch on of the MOSFET, once a valley

condition has been detected, it also serves as

the output overvoltage detector. In this case,

when the output voltage exceeds a specifi ed

limit due to a broken LED string the QR con-

troller will undergo a shutdown for protec-

tion purposes. Th e condition is triggered by

the TLE4305 which detects the overvoltage

condition via sense resistors and an internal

reference voltage.

Flyback controller suits LEDs

We’ve seen that a fl yback controller can

serve efficiently in DC-DC applications

where LED lighting is involved. Controllers

that contain a high-voltage start-up cell

can handle larger DC input voltages than

switching ICs specifi cally designed for LED

applications. Th is allows the designer to

accommodate more LEDs in a series con-

fi guration, ensuring that current is shared

equally by all LEDs in a string.

The QR controller achieves maximum

switching performance due to minimal

turn on losses which adds the benefi t of

reduced EMI. However both the fi xed-fre-

quency and QR controller designs can

accommodate dimming requirements by

simply adding a transistor to adjust and

control the loop’s feedback resistance. Th e

transistor controls the amount of current

supplied to the LED string to produce the

desired dimming eff ect.

Likewise the driver designer has the

option to program the desired current

based on the use of PWM to defi ne an oper-

ating point that establishes the desired LED

current. Th e designer should also bear in

mind that a QR controller enables full use

of the available bus voltage because it is not

bound to duty-cycle limitations typical in

fi xed frequency devices.

A signifi cant feature of the QR control-

ler scheme described here is that it also

affords the designer optimal efficiency

under dimming conditions compared to

that off ered by a fi xed-frequency control-

ler approach. Under light load conditions,

the reduction of the QR controller’s switch-

ing frequency minimizes associated losses

in the FET and inductor.

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_______________________

Page 78: LED_Feb_2013

last word

76 FEBRUARY 2013 LEDsmagazine.com

last word

Many companies in the lighting indus-

try are struggling with profi tabil-

ity in the transition to LED-based

lighting. Luminaire manufacturers are seeing

their R&D costs and stock levels increasing.

Th ey are writing off increasing quantities of

obsolete stock, and are facing increasing risk

of quality problems in the fi eld. Zhaga stan-

dards can help with these issues and acceler-

ate the adoption of solid-state lighting (SSL).

I spoke with a number of lighting man-

ufacturers who had increased their R&D

spending from around 3% of sales in 2006,

when they were designing luminaires with

conventional light sources only, to 6% of

sales last year, when 80% of the total went

on developing LED luminaires.

Such a high level of R&D spending does

not look sustainable for luminaire manufac-

turers. Costs will have to go down - not just

R&D costs, but also the cost of stock, stock

obsolescence, and the cost of quality. Why

has the R&D cost increased so much? Partly

because LEDs change faster than luminaires,

and partly because it is challenging to make

reliable luminaires that deliver the expected

long lifetime.

Modular design helps. In a modular lumi-

naire architecture, the LED technology is

separated from the optical and mechani-

cal parts of the luminaire. Th e R&D eff ort

can then be focused on maintaining the LED

module, a term that is used here loosely to

defi ne the part of the luminaire that con-

tains the LED technology.

Most luminaire companies already use

modular architectures – this is the only way

to develop and maintain a broad portfolio of

luminaires. While it may be obvious to sepa-

rate the LED technology, the choice of make vs

buy is less straightforward. Making your own

PCB with LEDs is attractive, and the cost is

lower than buying the equivalent off -the-shelf

module. This will get you luminaires with

minimum bill-of-materials (BOM) cost. On

the other hand, proprietary LED modules are

a burden for the R&D depart-

ment, and the design and main-

tenance of the modules will

increase your R&D cost.

Designing your own LED

modules has other pitfalls.

It is easy to get started, but

soon you will need variants

for other color temperatures,

light levels and CRI values.

Before you know it the R&D

department has doubled its

number of engineers.

Are you better off buying LED modules?

Not necessarily. They are more expensive,

and their integration into the luminaire still

needs careful engineering to make the lumi-

naire reliable. Furthermore, a module that is

competitive today may be outdated, or even

unavailable, a year from now. Th e dilemma

seems to be whether you should reduce the

R&D cost or the BOM cost. And what is the

eff ect on your stock levels, the risk of obso-

lete stock, and the diversity of your luminaire

product portfolio?

Zhaga off ers a way out of this dilemma. By

specifying the interfaces of a series of diff erent

LED modules, which Zhaga terms “LED light

engines,” Zhaga makes it possible for module

manufacturers to supply interchangeable LED

light sources. In the context of Zhaga, two

LED light engines are said to be interchange-

able when the luminaire manufacturer can

use either LED light engine without making

any change in the design (mechanical, optical,

thermal, or electrical) of the luminaire.

Luminaire manufacturers benefi t from

interchangeability because they can more

easily switch from one sup-

plier to another. The avail-

ability of a second-source

supplier reduces risk. Not

only will interchangeable

LED light engines be more

competitive, they are less vul-

nerable to supply issues, and

that helps reduce stock levels

and the risk of obsolescence.

A subtle benefi t is that inter-

changeable LED light engines

will off er more choice in terms of CRI, CCT,

lumen levels, lifetime, color stability, etc.

Th is off ers luminaire manufacturers the pos-

sibility to play with diff erent performance/

price levels in their luminaire portfolio with-

out increasing their R&D costs.

Th e impact of Zhaga is already visible.

For example, suppliers of linear indoor mod-

ules have started to off er products with the

mechanical dimensions and fi xation speci-

fi ed in Zhaga Book 7, even though that spec-

ifi cation has not been published yet. Even if

you choose to design and manufacture your

own linear modules, it now makes sense to

make them compatible with Zhaga Book 7.

You may want to purchase these modules

later from an external supplier.

MORE: www.zhagastandard.org

Zhaga helps SSL luminaire makersreduce costs and supply-chain risks

ZHAGA CONSORTIUM General Secretary MENNO TREFFERS explains that vendor-interoperable light

engines will allow companies to support broader LED-lighting portfolios with more features.

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Page 79: LED_Feb_2013

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Page 80: LED_Feb_2013

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