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Design Considerations for Effective LED Integration

Design Considerations for Effective LED Integration. David Scott-Maxwell R&D Manager Forge Europa Visible Solutions. Or…. Designing LED Lights is EASY …. Designing LED Lights is EASY …. … to Get WRONG ! …. How Easy?. How Easy?.

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Design Considerations for Effective LED Integration

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  1. Design Considerations for Effective LED Integration David Scott-Maxwell R&D Manager Forge Europa Visible Solutions

  2. Or…

  3. Designing LED Lights is EASY …

  4. Designing LED Lights is EASY … … to Get WRONG ! …

  5. How Easy?

  6. How Easy? An everyday example:24 LEDs in a magnetic clip lightPowered by 3 AAA batteriesCost £4.99

  7. How Easy? L70 ~1hr !

  8. How Easy? You can buy candles that last longer than this for the same money and give out the same light for 14 days continuously!

  9. So How do we Get it Right?

  10. So How do we Get it Right?

  11. We have to wear many different hats!

  12. LED Expert LED EXPERT

  13. LED Expert Cost {-per Lm / -per Cd / -per LED …} Availability {can you really buy what you want? …}Luminous efficiency {Lm/electricalW / Lm/opticW …}Light extraction efficiency {beam shape, size, uniformity …} Manufacturability {SMT reflowable, handling …}Physical size {lots of choice!} Light power rating {efficiency, eye safety …} Colour {range, colour rendering …} Reliability {MTBF, L70 …} Viewing angle {integral lenses, circular/elliptical …} Multi sourcing {desirable if possible …} Patents {hot issue! …} … LED EXPERT

  14. OPTICS Engineer OPTICS ENGINEER

  15. OPTICS Engineer LED EXPERT Transmissive optics (lenses etc) Cost Material choice {PC, PMMA …} Transmission efficiency {big concern …} Type {within-LED, separate, standard, bespoke …} Manufacturability {mounting, handling …} Beam pattern quality {colour stability, colour mixing …} Diffusion {prismatic, random …}Reflective optics (reflectors!) Growth area ?GLARE

  16. ELECTRONICS Engineer ELECTRONICS ENGINEER

  17. ELECTRONICS Engineer LED EXPERT CONSTANT CURRENT!Passive Current Control {resistors …}Active Current Control {linear, switched mode …}Low vs High Voltage AC / DCPower factor correctionDimming / modulation LED protectionTopology series / parallelLED junction temperature… CostEfficiencyElectromagnetic compatibilityReliabilityIntellectual property… all affect:

  18. THERMAL Engineer THERMAL ENGINEER

  19. THERMAL Engineer LED EXPERT LED temperature CRITICALLY controls: LED lifetime LED efficiencyThere’s only one place for heat to go – into the environment by: Conduction {to body of product, via water …} Convection {heatsinks …} Radiation {from body of product …}How to move heat: PCB {Metal core, FR4, exotic …} Thermal I/F {gap fillers, greases, phase change materials …} Heatsinks {standard, bespoke …} Enclosure {use product body itself …} Exotics …

  20. Chemist CHEMIST

  21. Chemist LEDs are NOT chemically inert!Sealed LEDs => reliability problemsUnsealed LEDs => oxidation problems LED silicone encapsulants can react with: Adhesives Cleaning agents Sealants Mould release agents …Conformal coatings – LED compatible? LED EXPERT

  22. PRODUCTION Engineer PRODUCTION ENGINEER

  23. LED “bin” grading {colour, brightness, voltage …}Production bin management {segregate, dither …} Binning standards {harmony may be emerging? …}ESD hazards {handling …}Mechanical issues {SMT handling, humidity …} Packaging {lens integrity …} Test {what/how?, eye safety …}… PRODUCTION Engineer LED EXPERT

  24. TEST Engineer TEST ENGINEER

  25. Test/measurement during DESIGN of: Optics {photometer, goniometer, spectrometer …} Electronics {efficiency, EMC …} Environmental {temperature, humidity, vibration …} LED Tj {LED pn junction temperature …}Test/measurement during MANUFACTURING of: Some of the above …LIFE TEST is very important as LED technology is moving so fast … TEST Engineer LED EXPERT

  26. Don’t Worry! LED EXPERT

  27. To design high quality LED lighting products you need to wear many different hats… Don’t Worry! LED EXPERT

  28. To design high quality LED lighting products you need to wear many different hats… LED EXPERT OPTICS ENGINEER THERMAL ENGINEER CHEMIST ELECTRONICS ENGINEER TEST ENGINEER PRODUCTION ENGINEER Don’t Worry! LED EXPERT

  29. Don’t Worry! You don’t need to be a magician to design high quality LED products… LED EXPERT

  30. You don’t need to be a magician to design high quality LED products…But you do need to understand many disparate disciplines… Don’t Worry! LED EXPERT

  31. You don’t need to be a magician to design high quality LED products…But you do need to understand many disparate disciplines…Or – Choose a partner with these skills! Don’t Worry! LED EXPERT

  32. Thank You ! LED EXPERT

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