OCTOBER 2012

LEDsmagazine.com

Retail
LEDs win in
refrigerated cases P. 23

Industrial
SSL in factory
lighting P. 51

TECHNOLOGY AND APPLICATIONS OF LIGHT EMITTING DIODES Materials

Thermally-stable
silicone optics P. 57

Architectural
Lighting
RGB LEDs illuminate
Miami Tower P.9
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______________________________

 ISSUE 55

october Cover Story

2012 The 47-story Miami Tower office building

has been relit externally with 216 Philips
Color Kinetics RGB fixtures connected
via a wireless DALI network to illuminate
the building faade with a palette of
more than 16 million colors (see page 9).

features
23 REFRIGERATED LIGHTING columns/departments
LED lighting fits in refrigerated display cases
Laura Peters
4 COMMENTARY Maury Wright
Networks are an unmistakable
match to LED lighting
33 CONFERENCES
The LED Show conference spanned components
to lighting design Maury Wright & Laura Peters
9 NEWS +ANALYSIS
Philips Color Kinetics lights
iconic Miami Tower
3M announces novel approach
43 COLOR SCIENCE to an LED retrofit lamp
Understand color science to maximize success Nexxus receives cash
with LEDs part 3 infusion, settles lawsuit
George Kelly, Avnet Electronics Marketing Cree extends SSL warranty to ten years
AkzoNobel expands capacity
for LED materials
51 INDUSTRIAL LIGHTING
Renesas and Virtual Extension
Textile and rubber manufacturer installs LED high- announce DALI LED demo kit
bay lighting Maury Wright
Lextar Electronics and Wellypower will
merge LED and lighting businesses
TI, Diodes and Allegro Microsystems
57 MATERIALS
introduce LED driver ICs
Moldable optical silicones enable LED lamp and
luminaire designs
Hugo da Silva, Dow Corning, Lighting Solutions 17 FUNDING+PROGRAMS
DOE updates SSL Manufacturing
R&D Roadmap
MSLLC announces draft of
63 STANDARDS
adaptive LED controls spec
SEMI committee progresses in HB LED standards
SEMI delegation seeks more
process Jianzhong Jiao, Osram Opto Semiconductors funding for LED manufacturing

67 DESIGN FORUM 72 LAST WORD Steve Paolini, Next Lighting

SSL will find use beyond general lighting as
Design considerations for enhancing LED LEDs control the electromagnetic spectrum
efficiency Thomas Davenport, Synopsys

LEDsmagazine.com OCTOBER 2012 3

commentary
Networks are an
unmistakable match
to LED lighting
I ntelligent control and network connec-
tivity are headed to a light near you. The
trend has been enabled in part because LEDs
must have driver electronics, and its a fairly
simple next step to add a low-end microcon-
troller and low-speed network interface to a
driver. But lighting controls would have been
a necessary evil anyway as controls maxi-
mize energy savings and lighting is the big-
gest energy sink on the planet. The network-
ing story has been a central theme at most
every LEDs and lighting conference of late.
Moreover, once you add intelligence in a
light, there is no telling what else you might
ask the light to do.
Were just back from the Street & Area
Lighting Conference (SALC) in Miami as I
write this. The keynote speaker, Niels Van
Duinen global marketing director at Phil-
ips Lighting, said that while LED sources
can deliver 50-70% energy savings, we
__________
need to save even more (www.ledsmaga-
______________ Th e need for more
zine.com/news/9/9/4).
savings is attributable to global popula-
tion growth and the related increases in
energy usage, as much as 40% of which is
used for lighting. Van Duinen said adap-
tive controls can bring savings to 80% and
predicted all lights would be connected
by Internet Protocol (IP) networks in the
future. We will have extensive coverage of
SALC in our next issue.
Meanwhile, speakers at The LED Show in
Las Vegas made similar statements about
networked lighting and controls (page 33).
You can do a lot in terms of adaptive con-
trols without networks. For example, sim-
ple occupancy sensors can slash energy
usage. Even local light sensors can enable
daylighting scenarios to save energy.
Still networks off er the greatest value
long term. Connectivity enables real-time
scheduling. You can read data from the
4 OCTOBER 2012
lights with a network such as real-time
energy usage or preventive maintenance
data such as temperature readings. And
networks will connect lighting to the smart
grid and even allow demand shedding.
Already some companies that sell net-
worked lighting have reported value from
unexpected usages. Networked lighting
with occupancy sensors can be used to find
vacant conference rooms, or even to know
if people are present in an area of a building
that should be vacant. Once you have net-
worked intelligence, you can do a lot with it.
Of course weve all heard by now that
LED lighting has the potential to convey
information wirelessly using the electro-
magnetic spectrum and in cases will serve
as a replacement for RF connections such
as Wi-Fi to computers. Indeed, in the clos-
ing session of The LED Show, Terrence
Walsh of Tempo Industries and Chip Israel
of Lighting Design Alliance both predicted
that lights would become part of the com-
munications network as opposed to being
simple nodes connected on that network.
Steve Paolini, CTO of Next Lighting,
authored our Last Word column in this
issue (page 72), and no one has been more
bullish on innovative uses of the electro-
magnetic spectrum than Paolini. Indeed
he mentioned using that spectrum for tele-
communications in his column. Paolini
also sees many other innovative uses of the
spectrum that can enhance our wellbeing,
provide health benefits, and make us hap-
pier. Much of that is better left to another
article or column. But even those appli-
cations require controls and would most
likely be networked.
Maury Wright, EDITOR
mauryw@pennwell.com
SENIOR VICE PRESIDENT Christine Shaw
& PUBLISHING DIRECTOR cshaw@pennwell.com
EDITOR Maury Wright
mauryw@pennwell.com
ASSOCIATE EDITOR Nicole Pelletier
nicolep@pennwell.com
SENIOR TECHNICAL Laura Peters
EDITOR laurap@pennwell.com
CONTRIBUTING Tim Whitaker
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MARKETING MANAGER Jennifer Landry
PRESENTATION MANAGER Kelli Mylchreest
PRODUCTION DIRECTOR Mari Rodriguez
SENIOR ILLUSTRATOR Christopher Hipp
AUDIENCE DEVELOPMENT Debbie Bouley
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ADVERTISERS index
Aeon Lighting Technology Inc. ............... 1
American Bright Optoelectronics .......... 13
Arc Solid State Lighting Corp. .............48
Beautiful Light Tech ............................ 15
Carlco Technical Plastics ..................... 14
Cree Inc. .......................................... CV4
CSA International ................................ 25
EBM-Papst Inc. ................................... 19
Edison Opto Corporation .....................53
Evergreen International Corp. ..............58
Ledlink Optics Inc. .............................. 11
Lightlab International .......................... 20
Linear Technology ............................. CV3
Lumens Co. Ltd. .................................38
Matrix Lighting Limited, Hong Kong .... CV2
MBN GmbH ........................................ 21
Mean Well USA Inc. ............................29
Nusil .................................................. 16
Optronics Laboratories........................46
Osram Opto-Semiconductors GmbH ..... 27
Sapa Industrial ...................................55
Seoul Semiconductor Co. Ltd. ............... 8
Shanxi Guangyu LED
Lighting Co. Ltd. ...............................69
Shenzhen Baikang Optical Co. Ltd. ........ 5
Shenzhen Bang-Bell
Electronics Co. Ltd. ..........................60
Shenzhen Refond
Optoelectronics Co. Ltd. ................... 18
Sichuan Jiuzhou Electric
Group Co. Ltd. .................................. 47

Fischer Electronik GmbH & CO KG .......12 Philips Lighting BV .............................. 31 Signcomplex Limited ...........................50

Future Electronics Inc. ........................40 Philips Lumileds ................................... 2 The Bergquist Company ......................35

Global Lighting Technologies ............... 49 Prolight Opto Technology .....................64 The BOC Group/Linde Electronics ........ 32

Indium Corp. ...................................... 10 Proto Labs Inc. ................................... 22 The Korean Consulate General ............36

Instruments Systems GmbH ................ 42 Recom Power Inc. ................... 37, 39, 41 Thomas Research Products ................... 7

Intertek ..............................................66 Roal Electronics USA Inc. ....................56 Underwriters Laboratories ...................45

Inventronics (Hangzhou) Co. Ltd. .........65 Samsung LED America ........................ 62 Unilumin Group Co. Ltd. ...................... 61

6 OCTOBER 2012 LEDsmagazine.com

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 ____________
news views
ARCHITECTURAL LIGHTING

Philips Color Kinetics

lights iconic Miami Tower
A landmark Florida office building called Miami Tower is
now lit by 216 Philips Color Kinetics LED luminaires with
the ability to generate 16 million colors and dynamic light
shows. The architectural retrofit will reemphasize the prom-
inence of the building on the skyline and provide the build-
ing owner with an energy-efficient solid-state lighting (SSL)
asset that it can use to attract new tenants.
The retrofit allows the building owner to paint the 47-story
tower with colors under computer control. In addition to pro-
viding everyday exterior lighting, the new system will be uti-
lized to present custom shows for occasions such as holidays The partnership of Philips Color Kinetics, LaSalle Invest-
or in support of building tenants or civic or charitable groups. ment Management, property manager Jones Lang LaSalle,
The project went live on Wednesday night September 19. and lighting designer and contractor LED Source was behind
Miami Tower has always been an iconic, easy-access the project. Jones Lang LaSalle began the preliminary plan-
downtown tower, said Ty Spearing, managing director at ning focusing on sustainable lighting back in January 2011.
building owner LaSalle Investment Management. Our goal is Previously 352 1000W and 40 400W metal-halide (MH)
to re-establish Miami Tower as a leader in technology, archi- lights lit the tower. The MH lights were limited to produc-
tecture and design, environmental sustainability, and on-site ing a few static colors using gels and consumed 878,518
amenities all of which Miamis top tenants demand. kWh annually. page 10

RETROFIT LAMPS

3M announces novel approach to an LED retrofit lamp

Th is Fall, materials specialist 3M lamp with availability that started
began shipping an LED-retrofit in September.
lamp that again proves that there The lamp design is decidedly
is no limit to the number of dif- different from the many other
ferent ways to apply solid-state approaches on the market. The
lighting (SSL) technology to the architecture greatly simplifies the
problem of designing an omnidi- driver design, as the the driver is
rectional bulb. The 60W-equivalent located in the relatively-spacious
3M LED Advanced light uses a light globe. Most other SSL retrofit lamps
guide that serves as the globe of cram the driver into the base and/or
the lamp and that carries and dis- neck of the lamp.
tributes the beam uniformly with The design allows air to flow into
the LEDs mounted just above the lamp just above the base and exit
Edison socket base. through slots in the upper half of the globe cooling both the
The new lamps produce 800 lm and are being sold in a 3000K LEDs and the driver. The LEDs are mounted facing upwards
CCT version that the company calls soft white light and a around the circumference of the neck of the lamp. The cool-white
5000K cool-white version. 3M says that the lamps will last 25 version uses 9 LEDs while the warm-white version uses 10 LEDs.
years based on a three-hour usage day and cost $1.63 per year A number of 3M materials are used in the lamp including opti-
to operate. Retailer Walmart is the initial source for the $25 cally clear adhesives used on the globe. The design also page 10

LEDsmagazine.com OCTOBER 2012 9

 news+views
Heat-Spring
Philips Color from page 9
The team replaced the MH lamps with
THERMAL INTERFACE 168 180W ColorReach Powercore fi xtures,
MATERIALS and 48 ColorGraze Powercore fi xtures. Both
utilize RGB LEDs that allow production of
any color instantly.
The fi xtures are controller by a Light Sys-
tem Manager (LSM) made by Philips Light-
ing that integrates hardware and light-con-
trol software in a PC-like enclosure. Gavin
Cooper, vice president of LED Source, said
The control side is an important part
because thats what makes this thing work.
The LSM connects via an Ethernet net-

work to a DMX gateway located on the 12th

floor of the building. On that floor wireless

3M from page 9
uses 3Ms Enhanced Specular Reflector
material in the light engine. And the lamp
uses 3M electrical connectors.
3M designed the light guide that forms
the outer structure of the lamp and uses
total internal reflection (TIR) technology
to distribute light around the globe. The
light-extraction elements are created with
white paint on the inside of the light guide
causing beams to reflect outside the lamp
in an omnidirectional fashion.
The lamp appears similar to a frosted
incandescent lamp and is primarily white
in the off state. The cooling slots are
apparent, but the look would not likely

 Show DMX systems from City Theatrical create the issue that say remote-phos-
Heat-Spring   transmit control information up the build-
 ing to the lights.

Each fixture has a unique Ethernet
address. The ColorReach fi xtures can essen-
 tially act as two different fi xtures with the
Solder
Ribbon top and bottom halves of the luminaire con-

trolled separately. The ColorGraze fi xtures
 can be addressed as four separate fi xtures.
Therefore the LSM has control of more than

 500 individual RGB sources.
Solder The displays will typically be rather con-
Preforms servative on a nightly basis given the pro-
fessional nature of the building. But the sys-
tem can implement various chasing-light
displays. Cooper said that LED Source had
created an image of the US flag on the back-
side of the building and he said Miami would
probably see some more dynamic presenta-
Learn more:
tions for occasions such as New Years Eve.
http://indium.us/F306
Despite the impressive capabilities, the
system will provide substantial savings
over the old lighting. The new system will
save 807,668 kWh and reduce carbon emis-
sions by 1.2 million pounds. The 92% energy
savings will combine with $20,000 savings
from materials and gels, $49,000 from main-
tenance, and $110,000 from rooftop lease
agreements with neighboring buildings,
upon which lights were mounted, to total
$260,000 annually.
The reduction in the number of fi xtures
was attributable to both the efficacy avail-
able in SSL products and the flexibility to
www.indium.com
mount the fi xtures virtually anywhere. Pre-
askus@indium.com
viously the MH lamps were mounted on the
ASIA  CHINA  EUROPE  USA building faade, and in setbacks on various
2012 Indium Corporation floors, as well as on neighboring buildings.
LED technology has reached a tipping
10 OCTOBER 2012
phor designs do, with the non-white color
in the off state, when lamps are used in
fi xtures that expose the bulb.
MORE: www.ledsmagazine.com/news/9/8/21
point where we can achieve better light
intensity than traditional lighting technolo-
gies, yet unlike traditional lighting systems,
we can work with the very tight space con-
straints and steep angles required to light
a building, said Jeff Cassis, general man-
ager of Philips Color Kinetics. In addition,
because LED is inherently more controllable
than other technologies, we have the abil-
ity to create fascinating effects with it. We
can also better focus LED light on the build-
ings facade, minimizing light spill while at
the same time respecting the neighbors and
night sky.
MORE: www.ledsmagazine.com/news/9/9/16
BUSINESS
Nexxus receives cash
infusion, settles lawsuit
Nexxus Lighting, a maker of LED replace-
ment lamps based in Charlotte, NC, received
a $6 million investment from a private
equity firm Aston Capital LLC. Subsequently
Nexxus announced a settlement agreement
ending the pending patent litigation brought
by Royal Philips Electronics.
Aston now owns 73% of Nexxus common
stock. Robert LaPenta, chief executive offi-
cer (CEO) of Aston, has become Nexxuss
new chairman. We view the market for LED
lighting to be in the early phase of adoption
LEDsmagazine.com
____________________
 news+views
and we see Nexxus Lighting, with their prod-
uct lines and intellectual property, as a plat-
form on which to build and grow in the mar-
ket, LaPenta said.
The proceeds of the investment are being
to cool to protect to connect used to pay off about $2.5 million of short-
term debt and to fund the settlement of the
Electromechanics Philips patent lawsuit. Philips will grant
for LEDs Nexxus Lighting an ongoing, royalty-bear-
 various LED heatsinks ing license to the comprehensive portfolio
 of patented LED technologies and solutions
  offered under Philips LED luminaire and

executive vice president of lighting. With
leading LED research and development, a
strong financial balance sheet and some
of the industrys longest-running field LED
lighting installations, the new 10-year lim-
ited warranty underscores Crees commit-
ment to the long-term performance and reli-
ability of our products.
The warranty will clearly benefit the com-
mercial customers. Doug Knisely, director
of building and petroleum construction at
Sheetz said, The new warranty further val-


 retrofit bulb licensing program. The license
  
 ture and sell LED-based lighting products,
 
For more details please check
our website: fischerelektronik.de
______________
Fischer Elektronik
GmbH & Co. KG
N

idates our decision to use Cree LED lighting.
allows Nexxus to continue to manufac-
including the Array brand of LED replace-
ment light bulbs.
The opportunity for creating, developing
and selling creative new LED lighting sys-
tems is expanding rapidly and we believe
that combining access to the Philips portfo-
lio of intellectual property with our own pat-
ented technology will give Nexxus Lighting
a tremendous platform from which to pen-
etrate the growing lighting market, stated
Mike Bauer, president and CEO of Nexxus
Lighting. We are pleased we could come to
mutually agreeable terms and can now refo-
cus our business on the large growth oppor-
tunities we see for LED lighting.
MORE: www.ledsmagazine.com/news/9/9/20
SSL WARRANTY
Cree extends SSL
warranty to ten years
Cree lighting is extending its warranty to ten
years on what it classifies as nearly all new
commercial lighting products for indoor
and outdoor applications. The company is
clearly gaining confidence in all aspects of
SSL product design and lifetime, because the
warranty in an LED-based lighting product
ultimately covers many elements beyond the
LEDs, including the driver electronics.
The products exempted from the extended
warranty include the LR24 troffers that are
being replaced by the CR series, and the CR
Industry leading energy efficiency, lifetime
performance and quality make Cree LED
lighting a smart choice.
MATERIALS
AkzoNobel expands capacity
for LED materials
AkzoNobel has announced plans to boost
capacity at one of its US sites in order to
meet increasing demand for metalorganic
(MO) compounds that are used in the pro-
duction of LEDs. The investment, which is
described as being at the multi-million
dollar level, will be made at the companys
Battleground facility in Texas. AkzoNobel is
a global chemical company with headquar-
ters in the Netherlands.
The company plans to extend its trimethyl
aluminum (TMA) unit, as well as building a
new trimethyl gallium (TMG) plant. This will,
says AkzoNobel, consolidate the plants sta-
tus as the largest of its kind in the world.
TMA and TMG are used as the source
materials for aluminum and gallium, respec-
tively, in the epitaxial growth of LED mate-
rials via metalorganic chemical vapor depo-
sition (MOCVD). The expanded TMA unit is
expected to be completed in the third quar-
ter of 2013, while the new TMG plant will be
ready in August 2014.
The LED industry has been experiencing
strong growth, well in excess of 20 percent
per annum, explained Werner Fuhrmann,
AkzoNobels executive committee member



 

family of downlights. Cree is also exempting responsible for specialty chemicals. This
  some directional retrofit lamps as well as some investment will make production more cost-

  lighting controls, but the bulk of the commer- efficient and ensure that we continue supply-

_____________________
cial line will receive the extended coverage. ing our customers with a highly specialized
We exhibit: 21.-22.11.12, Added to the energy savings LEDs offer product which is playing an increasingly
Forum LED in Paris, stand B7 over traditional technologies, this warranty important role in 21st century technology.
is a win-win for everyone, said Ty Mitchell, MORE: www.ledsmagazine.com/news/9/9/22

12 OCTOBER 2012 LEDsmagazine.com


SSL CONTROLS
Renesas and Virtual Extension
announce DALI LED demo
kit at SIL Europe
Renesas Electronics Europe and Virtual
Extension showcased a new LED lighting
demo kit at Strategies in Light (SIL) Europe
that includes a digital addressable lighting
interface (DALI) gateway and eight wireless
nodes. The kit is based on Renesas RL78/I1A
microcontroller (MCU) that handles LED
control, control of LED driver electronics,
and communication functions.
The RL78/I1A MCU is optimized for light-
ing applications and is part of Renesas low-
power-optimized 16-bit RL78 family. The
MCU integrates the DALI functionality along
with nonvolatile Flash memory and a broad
set of peripheral functions including data
converters and pulse-width modulation func-
tions needed for driver electronics control.
DALI is an industry standard for lighting
control and is especially popular for com-
mercial building applications in Europe.
Renesas says that DALI is simpler and less
expensive to implement relative to other
building-automation networks.
The DALI Demo Kit connects to a DALI
network via the gateway functionality
implemented on the MCU. The gateway, in
turn, communicates with individual wire-
less lighting nodes over the VEmesh mesh
network developed by Virtual Extension.
The eight wireless nodes in the kit can
each control three channels of LEDs. More-
news+views
over, each channel can be assigned its own
DALI address. A DALI master can control
the channels individually or broadcast com-
mands to multiple addresses.
MORE: www.ledsmagazine.com/news/9/9/11
BUSINESS
Lextar Electronics and
Wellypower will merge LED
and lighting businesses
The boards of directors of Lextar Electronics
and Wellypower Optronics have approved a
merger in which the latter will be absorbed
into Lextar. The merger, based on a stock
swap of two Wellypower shares for one
Lextar share, is targeted for completion on
February 1, 2013. Both companies manu-
facture LEDs, among other things, and the
combined operations will make Lextar the
second largest LED maker in Taiwan trail-
ing only Epistar.
Lextar believes the integration with
Wellypower will be effective and resource-
_________________
 news+views
ful, and will help the companies maintain a
competitive edge in the LED market, said
David Su, chairman of Lextar. Lextar has
resource management, production and sup-
ply chain experience with company merg-
ing back in 2010 where it merged with the
largest LED backlighting maker at the time,
Lighthouse. Lextars merger with Welly-
power this time around will provide the
two sides more talent and resources, and
will increase Lextars advantages in the
ever-quickening and evolving LED light-
ing market.
Lextar is a subsidiary of AU Optronics,
while Au Optronics is also an investor in
Wellypower. Lighting manufacturer China
Electric is also an investor in Wellypower
and a partnership between the two includes
Wellypower supplying T5 tubes for the China
Electric TOA brand. Lextar will now also have
a closer relationship with China Electric with
High Bay Reflector
the company saying they will be able to
Archimedes enhance mutual competitiveness in the LED
lighting market.
For Wellypower, the merger offers the com-
pany immediate access to a deeper LED tech-
nology portfolio at a time when the lighting
industry is transitioning to SSL. While the
company sells packaged LEDs, it buys the
chips and specializes in the packaging.
Wellypower believes it will obtain tech-
nological and management resources after
Large Source Reflector
the merger, which will be beneficial in quick-
Newton ening the companys transformation into an tions of LEDs in a single series string or mul-
LED one, said Allen Huang, chairman of
Wellypower. The merger will also increase
the companys competitiveness and will [be]
beneficial for stockholders.
MORE: www.ledsmagazine.com/news/9/9/9
DRIVER ICS
TI, Diodes, and Allegro
Hubble Microsystems introduce
Free Form Optic LED driver ICs
Texas Instruments (TI) introduced the new
LM3463 driver IC that can handle six chan-
www.carclo-optics.com nels with as many as 28 LEDs per string for
high-output solid-state lighting (SSL) appli-
cations such as street lights and indus-
trial high-bay lights. Allegro Microsystems
November 6th - 9th
announced a single-channel 3A driver IC
Earls Court,London based on a buck topology. And for low-light
Stand E08 applications, Diodes Inc. announced the
AL5812 driver IC optimized for use with
14 OCTOBER 2012
mid-power LEDs.
The TI driver IC can supply an out-
put voltage that ranges from 12V to 95V.
The range allows the driver to work with
large strings of individual emitters or the
broad array of multi-die packaged LEDs
that manufacturers such as Cree, Philips
Lumileds and others have developed with
varying forward-voltage configurations.
The dimming implementation is flexible
both in terms of how the dimming settings
are conveyed and applied. Product design-
ers can control dimming directly using a
pulse width modulated (PWM) signal gen-
erated by a component such as a microcon-
troller. Alternatively, a design can use a DC
voltage level to control the dim level. Th e
third option is a digital transmission of a
series of data bytes that convey the setting.
While six channels is sufficient for most
applications with LEDs getting brighter on
an ongoing basis, a design can cascade mul-
tiple LM3463 ICs to drive even more strings.
In such applications, one LM3463 serves as
the master and settings such as dimming
levels are then passed along to slave devices
using the serial data control scheme.
Meanwhile, single channel driver ICs such
as the new Allegro Microsystems A6211 can
integrate an output MOSFET and still offer
flexibility in terms of output voltage. The
driver IC supports output voltages ranging
from 6V to 48V to supply varying configura-
tiple parallel strings.
Designed for consumer, industrial, and
architectural lighting applications, a single
external current-sense resistor allows the
driver IC to be configured for the LEDs and
topology used in a specific application. The
driver supports dimming via a PWM input.
Moving to the opposite end of the driver
IC spectrum, the new Diodes AL5812 IC sup-
plies 150 mA of current and is optimized for
use with the growing class of mid-power
0.5W LEDs. Diodes specifically targets appli-
cations such as signage and low-light SSL
applications with the product.
The 60W output would typically drive a
single string of as many as 16 mid-power
LEDs. Current is set via an external resis-
tor. The driver IC does not support dimming.
The design is optimized for a minimal bill of
materials and low cost.
MORE: www.ledsmagazine.com/news/9/9/18
LEDsmagazine.com
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Building on our 30 years of experience providing custom silicone solutions, were expanding USA +1 805-684-8780
our technological capabilities across the globe. At NuSil, weve dramatically increased the size Europe +33 (0) 4 92 96 9331
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production, across the country or around the world, NuSil is there for you in a big way. nusil.com/led
________
2012 NuSil Technology LLC. All rights reserved.
 funding
programs
MSLLC announces
draft of adaptive
LED controls spec
On the final day of the Street &
Area Lighting Conference (SALC)
in Miami, Florida, Edward Smalley,
the director of the Municipal Solid-
State Street Lighting Consortium
(MSSLC), announced that the "Model
DOE updates SSL Manufacturing Specification for Adaptive Control and
Remote Monitoring of LED Roadway
R&D Roadmap Luminaires" document was avail-
able for review (www1.eere.energy.
____________
The US Department of Energy (DOE) has of state-of-the-art modules, light engines, gov/buildings/ssl/consortium.html).
published the 2012 edition of the Solid- and luminaires; development of high-speed, Th is much anticipated model spec has
State Lighting (SSL) Manufacturing R&D nondestructive test equipment and metrics proved to be a tougher challenge than
Roadmap, which seeks to guide research for each stage of production; identification did luminaires. One reason is that there
programs in LED and OLED manufactur- of critical issues with back-end processes for are many elements in a municipal con-
ing with the goal of meeting aggressive cost packaged LEDs; and improved manufactur- trol system including network and soft-
targets for 2015 and 2020. This update is the ing of phosphors or other down converters. ware elements. The draft clearly shows
result of recommendations made at the April Specific targets for 2015 include a 2 the complexity of the controls area
meetings of OLED and LED expert panels as increase in throughput, reduction in OEM and the flexibility that had to be in the
lamp price from document. For example, users will be
Relative manufacturing cost ($)
$50/klm to $10/ able to specify a variety of wired and
1.0 Assembly klm, 50% reduc- wireless network types. The spec also
0.9 tion in assembly includes the option of specifying the
Driver
0.8
cost every 2-3 years maximum amount of time it takes a
0.7 Mechanical/thermal and color con- network to deliver a command to a
0.6
Optics trol improvement street light. And there are many options
0.5
0.4 from 7 standard of how to implement control and com-
0.3 LED packages deviation for color missioning software.
0.2 matching (SDCM) Like the luminaires model spec, the
0.1 to 4 SDCM. controls document is meant to serve as a
0.0
2011 2013 2015 2020 The roundtable template that users can follow to create
Source: Data provided by 2011 Manufacturing Roundtable attendees discussion of LED a precise specification that meets their
packaging manu- individual municipality needs. More-
FIG. 1. Projected cost track for an LED-based A19 60W
facturing revolved over, the document will establish a com-
replacement lamp. Targets assumes 66% reduction in $/klm
around using lower mon set of terms that suppliers and cus-
by 2015 and 80% by 2020, based on DOEs 2012 MYPP for
cost materials and tomers can use to ensure consistency.
integrated lamps.
manufacturing pro- It's hard to say when the first pur-
well as work performed by 200 attendees at cesses within the LED package. Specifically, chases of control systems based on the
the 4th annual SSL Manufacturing R&D by 2015 it calls for a 2 increase in packaged specification might occur. The model
Workshop, held in June in San Jose, CA. The LED throughput each year, 50% reduction specification for luminaires was fi nal-
roadmap may be downloaded at www.ssl. is assembly cost/klm every 2-3 years, 50% ized about one year ago. At SALC this
energy.gov/techroadmaps.html, while the reduction in the cost of packaging ($/mm2) year, a group of small municipalities in
workshop report can be accessed at www. ___ every 2-3 years and a 50% reduction in the Iowa announced they had used that lumi-
ssl.energy.gov/sanjose2012_materials.html. cost per package ($/klm) every 2-3 years. naire spec to make a purchase becom-
Importantly, this years roadmap was The test and inspection discussion called ing the fi rst to do so. But the controls
revised to focus more tightly on six goals for support for the development of high- spec could be in for a longer review.
overall due to budget cuts. Four priority speed, high-resolution, non-destructive
tasks for LEDs were identified including sup- test equipment with standardized test pro- MORE: www.ledsmagazine.com/news/9/9/13
port for the development of manufacturing cedures and appropriate met- page 18

LEDsmagazine.com OCTOBER 2012 17

 funding programs

Roadmap from page 17 Relative manufacturing cost ($) The OLED priorities are
rics within each stage of the 1.0 focused on improving OLED
value chain for semiconductor 0.9 deposition equipment and OLED
wafers, epitaxial layers, LED die, 0.8 materials. The cost target is <$100
Packaging
packaged LEDs, modules, lumi- 0.7 /m2 of good panel produced.
naires, and optical components. 0.6 The current price of OLED
0.5
One specific area of interest Phosphor luminaire samples is $1500-
0.4
involves the high-speed mon- 0.3
Wafer processing $2000/klm and Philips has indi-
itoring of light output, color 0.2 Epitaxy cated that panels can be pur-
quality, and color consistency at 0.1 Substrate chased in the $800/klm range.
the wafer level at LED operating 0.0 The 2012 Roadmap assumes that
2011 2013 2015 2020
temperature. Such test equip- Source: Data provided by 2011 and 2012 Manufacturing Workshop and Roundtable attendees by 2015, OLED R&D lines will be
ment would facilitate the auto- converted to production lines
mation of LED and phosphor FIG. 2. Projected LED package price track. and the OLED luminaire cost
matching and accelerate final can be brought to $50/klm while
device binning. turing cost reduction rather than price reduc- OLED panel cost will be $30/klm. The targets
Regarding improved manufacturing of tion. Therefore, it is critical when examining for 2015 are based on estimates by Moser Baer,
phosphors, by 2015 the roadmap calls for the charts such as the manufacturing cost of whose strategy is to minimize cycle time while
larger batch sizes (from 1-5 kg to 20 kg), a an LED-based A19 60W lamp (Fig. 1), which using relatively small substrates.
50% reduction in the cost/kg every 2-3 years, is based purely on manufacturing costs, that Overall, OLED production cost needs to be
raising phosphor utilization from 50% to it not be confused with data that tracks the reduced by 20-100 to make OLEDs compet-
90%, and reducing cost/klm by 50%. packaged LED cost and does include gross itive with, for instance, edge-lit LED lumi-
One of the more significant changes to the margin (Fig. 2), and is therefore more legiti- naires that produce diff use light.
2012 document is the emphasis on manufac- mately referred to as a price. MORE: www.ledsmagazine.com/news/9/8/26

__________
 the spotlight shines on efficiency

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/ActiveCooling
________________________

or speak with an application engineer at (860) 674-1515

the engineers choice

 funding programs

DOE releases cost model

for manufacturing estimates
of LED components
The DOE has developed a model that allows companies to assess the
effect on manufacturing cost of changing different aspects of their
LED manufacturing process flow.
The Modular LED Cost Model (LEDCOM), which was developed
by a DOE working group in response to feedback from previous DOE
workshops and roundtables, provides a simplified method for ana-
lyzing the manufacturing costs of an LED component.
The model was introduced as part of the newly-revised SSL Man-
ufacturing R&D Roadmap 2012.
The LEDCOM model focuses on the major cost elements of LED
manufacturing and includes preliminary raw data and a basic
manufacturing process flow. These provide a starting point and
can be customized by the user to model different processes, mate-
rials, and equipment.
The tool is intended for those involved in the manufacturing of
LED packages, from material and equipment suppliers, to epitaxy
growers, to wafer producers, to chip manufacturers and packagers.
For example, the tool can be configured to evaluate the impact of
changes to the substrate size and type, the fabrication process, raw
materials costs, and the manufacturing equipment used.
The LEDCOM tool can be downloaded from the DOE SSL website
as a zip file that contains the LEDCOM model as an excel worksheet,
the backend database, and an operating information document.
MORE: www.ledsmagazine.com/news/9/9/3

SEMI delegation seeks more

funding for LED manufacturing
A delegation of SEMI members and other stakeholders in LED
manufacturing met recently with the US DOE assistant secre-
tary of energy David Danielson and his senior staff to advocate
increased support for R&D and manufacturing in solid-state
lighting (SSL).
By demonstrating that LED-based SSL delivers excellent ROI
on taxpayer investment, SEMI hopes to secure increased levels of
funding to support LED manufacturing in the US.
The group based its argument on the significantly higher
return-on-investment (ROI) from government funding demon-
strated by LED-based SSL over renewable energy sources and
other energy investments.
SEMI is the global industry association serving the manufactur-
ing supply chain for the micro- and nano-electronics industries,
including semiconductors and LEDs.
Support for an appropriately-funded and effective US LED man-
ufacturing policy is being driven by the FALCON Lighting Consor-
tium, a group of SSL industry proponents led by LED maker Philips
Lumileds, and equipment makers (and SEMI members) Applied
_________________________ Materials, Veeco, KLA-Tencor and Ultratech.
SEMI and FALCON say that they have long advocated increased

20 OCTOBER 2012 LEDsmagazine.com

 funding programs

Program FY11 DOE 2009 generation 2035 generation in US (quads, 2035 relative
tion afforded by SSL will have
request ($ million) in US (quads*) projected) Ref in each cell investment per quad greater impact on US energy
use than the supported renew-
Solar 302.4 0.068 4.7 (EIA est.) 1.00
able energy-generation technol-
Hydro 40.5 2.70 2.7 (www.grist.org) 0.23 ogies. SEMI says that SSL can
Geothermal 55.0 0.38 1.5 (DOE MYPP-MIT study 2.25 deliver 4.0-6.0 quads of annual
Biomass 220.0 2.01 4.3 (EIA est.) 0.80 energy savings, which repre-
Wind 122.5 0.69 2.12 (renewable.energy.focus.com) 0.90 sents a 10-20 times higher ROI
Lighting 26.8 6.0/4.0** 6.0/4.0** (savings) 0.10
than other energy investment
(savings) alternatives. The ROI argument
* US Energy Information Administration (EIA) 2009 Annual Energy Review
is summarized in Table 1.
** DOE est. 4.0 quads (http://www1.eere.energy.gov/buildings/ssl/tech_reports.html), Jan 2012: FALCON estimate against current usage 6.0 quads During the meeting, the
group urged greater balance
DOE support for developing SSL in the US, particularly in the area of for energy funding in the FY2013 and future budgets. Richard Solarz,
manufacturing, but are also supportive of other SSL-related efforts. senior director of technology at KLA-Tencor, and Randy Moorhead,
SSL manufacturing R&D is part of the long-term SSL program run VP for government relations at Philips Electronics, co-leaders of the
by the DOEs Building Technologies Program. group advocating for greater DOE support for SSL, stated, Accord-
LED manufacturing received over $23 million in grants in areas ing to the Energy Information Administration (EIA), on a dollar-per-
such as metrology, lithography and deposition R&D as part of the unit-of-production basis, the level of subsidies received by the wind
American Recovery and Reinvestment Act in 2009. Since that time, and solar industries were almost 100 times greater than those for
funding has been reduced, although considerable bipartisan sup- conventional energy. We believe that it is generally understood that
port has increased funding levels above the requests put forward by conventional energy conservation efforts, specifically [those involv-
the DOE to the Energy and Water Appropriations Subcommittees. ing] lighting, are under-supported.
During the meeting, SEMI explained that energy conserva- MORE: www.ledsmagazine.com/news/9/9/5

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lighting | REFRIGERATED CASES
LED lighting fits perfectly in
refrigerated display cases
LED lighting in refrigerated cases provides dramatic energy savings, lower maintenance cost and
more appealing displays, reports LAURA PETERS.
R
efrigerated display lighting (RDL)
represents one of the more perfect
applications for LEDs. Because flu-
orescent tubes can be replaced with LED
strips and reduce energy usage by 60%,
retailers are beginning to implement LED
case lighting on a wider scale. Typically,
a store can realize return-on-investment
(ROI) after 2-3 years using LED-lit coolers.
In addition, since LED fi xtures give off little
heat relative to a fluorescent tube, an addi-
tional energy break is realized on compres-
sor cooling. LEDs love the cold; the colder
they are the longer they last. We are able to
design fi xtures that are rated for 100,000
LAURA PETERS is the Senior Technical Editor
of LEDs Magazine.
hours, said Jamie Pearson, senior value
stream manager of Lithonia Lighting, part
of Acuity Brands.
Fluorescent tubes provide a diff use light
in all directions, whereas LED lighting fi x-
tures have been designed to provide direc-
tional illumination at 70-160 as needed in
the case. Importantly, the quality of light
in the case can also be improved to reduce
glare, eliminate hot spots and make the food
and packaging more appealing through bet-
ter color rendering. We recognized early
on that many companys products would be
within 10% of each other in energy savings.
So we focused on providing the best light
with the best color rendering and greatest
uniformity, said Paul Kelly, vice president
of market development for Nualight.
This merchandizing effect of LED lighting
is being applied beyond the refrigerated cases
themselves. Many grocery stores, specialty
shops and convenience marts have decided
to implement LED lighting throughout the
store and in outside parking lots and gas sta-
tions. For instance, Jernimo Martins Group
(Fig. 1 and 2) recently installed LED lighting
inside and outside its supermarkets in Por-
tugal (www.ledsmagazine.com/news/9/2/3),
which we will cover in more detail below.
Notably, Walmart has set a goal to use 100%
LED lighting in all of its 5,366 stores through
______
new construction and retrofitting (www.leds-
magazine.com/press/33495).
_________________
As will be discussed, the adoption rates
of RDL differ among Europe, North Amer-
ica and Asia. The fastest adoption has been
FIG. 1. An all-LED
supermarket in Portugal used
Arquiled fi xtures and controls
and Oslon LEDs from Osram
Opto Semiconductors (photo
courtesy of Arquiled/Osram).
FIG. 2. The gas station uses controls to further reduce lighting costs (photo courtesy of Arquiled/Osram).

seen in North America, where incentives study estimated there were 14 million sin- and beverage retailers have countless options
have shortened the time to ROI. gle-lamp fi xtures and 6 million dual-lamp when it comes to choosing a provider of LED
fi xtures in horizontal cases available for ret- refrigerated display lighting. Providers include
Refrigerated case lighting options rofit, according to Cheryl Ford, vertical mar- well-known companies such as Acuity Brands,
Refrigerated display cases are available in keting manager for Osram Sylvania. GE Lighting, Nualight, Osram Sylvania, and
many styles and sizes, but the market over- The vertical units are used for packaged Philips Lighting, but there are numerous other
all generally comes down to vertical freezer foods, while the horizontal cases are used providers from Europe, North America and
cases with doors and horizontal refriger- for fresh dairy and meats. Though an ingress Asia. The qualified product list of the Design-
ated cases without doors. The lighting in protection (IP) rating is not common for the Lights Consortium (DLC), which includes both
the vertical cases run vertically along each freezer lighting fi xtures, many users spec- vertical and horizontal RDL, contains prod-
side of the door, and is generally 5-ft tall. ify an IP rating of IP64 or IP65 for the hori- ucts from 19 manufacturers.
In horizontal cases, typically there are one zontal cases to ensure the fi xtures can with- The DLC relies on LM-79 data from a qual-
or two 4-ft fi xtures that run at the top of stand wet cleaning. ified third-party testing lab to demonstrate
the case (canopy lighting) and the base of At first glance, it would appear that food that fi xtures meet minimum performance
the case (shelf lighting). In Europe, another
common design employs a row of vertical
coolers on top and horizontal coolers on
the bottom.
The worldwide market for lighting in
refrigerated display cases is huge, espe-
cially the retrofit market. Case makers such
as Hussmann and Kysor/Warren are selling
new refrigerated cases with LED lighting
already equipped in the case. But for exist-
ing stores, new cases cost in the range of
$5000 for a three-door unit, so most man-
agers choose to retrofit the case lighting.
In a study from 2010, Osram Sylvania
estimated that there were roughly 10 mil-
lion vertical case freezer doors available
for retrofit, and nearly 20 million horizon-
tal linear 4-ft fi xtures in open refrigerated FIG. 3. The Shiver fixture from Lithonia Lighting uses a 90 cutoff angle to reduce glare
cases available for retrofit in the US. The on merchandise and keep light inside the case (photo courtesy of Acuity Brands).

24 OCTOBER 2012 LEDsmagazine.com

   

   

  

  
  
 
 
    
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lighting | REFRIGERATED CASES
criteria. These include a luminous efficacy
of 55 lm/W, CRI of 70, light out-
put of 50 lm/ft for end fi x-
tures or 100 lm/ft for center
fi xtures, and a zonal lumen
density of 90% from 0-90. Fig.
3 shows a typical light distribu-
tion when zonal lumen density is con-
centrated in this way.
A 5-ft fluorescent tube uses 60W of power
(total wattage for 58W lamp and ballast).
Todays 5-ft LED fi xtures typically use 12W
(right or left end unit) or 18-24W (center
unit). Both bi-pin and bracket-based ver-
sions are offered (Fig. 4). A driver is needed
to step down from mains power to 24V. It is
typical that one driver is required per door
(2 fi xtures).
Some LED fi xtures use a series of low-
wattage LEDs, typically 0.5W or 1W, along a
strip, while others use high-powered LEDs
spaced along a metal fixture. Most units
have specially designed optics. Some com-
panies offer broad product lines in a range
of sizes and color temperatures, while other
companies target only the most common
case sizes and product depths.
Retailers typically choose LED fi xtures
with cooler color temperatures for freez-
ers whereas a warmer CCT of 3000K is
FIG. 4. The LEDstixx fi xtures in bracketed or bi-pin versions. The driver can handle 4-6
fi xtures, reducing installation complexity (photo courtesy of Osram Sylvania).
26 OCTOBER 2012
more suitable for
meats, fish and seafood.
Products with a color rendering index
(CRI) of 70 to as high as 95 are commer-
cially available, which compares to a CRI of
85 for fluorescent lamps. For instance, Phil-
ips offers its Affinium LED modules (Fig. 5)
in color temperatures of cool white (5600K)
or neutral white (4100K).
Though a higher price is associated with
the higher CRI LED fixtures, retail store
owners understand the greater visual appeal
associated with better color rendering.
While initial use may be confi ned to high-
end products such as meats and cheeses, the
more LED pricing comes down, the easier it
becomes to afford the better light.
Susan Fowler, LED refrigerated lighting
product leader for GE Lighting summarized
the design of the Immersion RV40 LED fi x-
tures (Fig. 6), as products that optimize
energy savings while providing 750-1100 lx,
hiding the view of the light source, focus-
FIG. 5. The Affinium LED LDM400/405
modules are available in 59-in or 67-in
lengths and color temperatures of 4100K
or 5600K (photo courtesy of Philips).
ing light on the packaging versus spilling
onto the floor or doors, and creating uniform
light in the case. GE offers these fi xtures in
3500K, 4000K and 5000K color temperatures
and sizes of 30, 36, 48, 60 and 70 in. The 60-in,
4000K model produces 1070 lm (213 lm/ft)
and requires 18W of power.
Regional differences
Retailers in North America, Europe and Asia
are at different stages of RDL adoption. The
types of cases and sizes differ by region as
well. Fowler noted that North American
stores tend to be larger in general than stores
in Europe. She stated that while all regions
are interested in reducing energy cost and
maintenance cost with LED fi xtures, west-
ern countries tend to focus on energy and
light quality, while eastern regions tend to
focus more on payback.
In North America, the utility rebates
have accelerated adoption. North America
is miles ahead of Europe, said Kelly. Per-
haps 40% of the North American market
has been retrofit in the freezer segment,
he added. Kelly predicted that LED lighting
for all refrigerated cases will become the de
facto standard in North America by 2014.
Another difference is that product tends
to be situated closer to the door in cases
in the US. Some companies offer a product
line that accommodates these differences.
Speaking to Osrams approach, Ford said,
The distance of the lighting fi xture to the
merchandise is key. If your shelf depth is up
to 4 in one product is used, 4-8 in a sec-
ond product and 8-10 in a third product.
Brief history of case lighting
Refrigerated cases have been lit by T8 fluores-
cent tubes for several decades. GE Lighting
was the first company to install LED light-
ing in refrigerated cases at Walmart in 2006
(www.ledsmagazine.com/news/3/11/16). At
LEDsmagazine.com
ledlight.osram-os.com/farther

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Our commitment to constant improvement, LED technological innovation and the highest
lighting quality mean were constantly monitoring the next big thing. And as your partner,
no one can provide better service or flexibility than we can. So look ahead look to
OSRAM Opto Semiconductors. See what were up to today, for tomorrow.
lighting | REFRIGERATED CASES

that time, the LED fi xtures used 41W

of power each, replacing 59W fluores-
cent tubes. Because LED refrig-
erated display lighting was
one of the first LED catego-
ries created for grocers, the
technology has had time to FIG. 6. The Immersion NV40 for vertical
evolve and drive the payback down signifi- freezer cases uses 7 LED modules to
cantly, said Fowler. recently selected Nualight to supply produce 1170 lm at 18W and 4000K
Such early installations are just now refrigerated case lighting for all its new and color temperature (photo courtesy of
passing their warranty period of five years retrofit store projects. Nualight stated that GE Lighting).
or 50,000 hours of operation. Fowler stated its LED lighting will reduce lighting-related
that testing of these systems has shown they energy consumption for Sainsburys by 70% $37,000 annually. The reliability of an LED
currently perform at or better than the pre- in low-temperature cases and by 40% in system was a critical factor in our payback
dicted values after five years. However, many medium-temperature cases. Sainsbury was equation, as was the impact energy sav-
customers are opting to upgrade to the new- the first retailer to use Nualights Perfi no fi x- ings would have on shortening that time
est LED fi xtures because of the higher effi- ture, which is designed to address the chal- period. GEs Fowler noted that for retrofit,
ciency. For instance, current generation GE lenges of reflective packaging and visibility ROI strongly impacts the lighting selection.
fi xtures require 45% less power than the fi x- of the LEDs in multi-deck cases (www.leds-
_______
tures produced in 2008. _________________
magazine.com/news/9/2/31). ROI and energy savings
In 2006, the Lighting Research Center Food City first evaluated vertical-case As shown with these case studies, the
at Rensselaer Polytechnic Institute con- LED lighting systems in its Abingdon, VA energy savings for LED lighting in refriger-
ducted a study comparing LED and fluores- store and later retrofitted 89 stores using ated cases typically averages 60% and can
cent lighting in refrigerated cases. The study GEs NV40 fi xtures (Fig. 7). In total 7400 dis- be 70% or greater when occupancy sensors
determined that shoppers overwhelmingly play cases were upgraded, providing a light- are used. In the US, the upfront cost of LED
preferred the LED-lit cases for displaying ing energy and refrigeration cost savings of lighting retrofits can be offset by federal tax
packaged foods of many different colors. The $337,000. Keith Norton, director of engi- savings and local utility rebates.
shoppers found the LED lighting made the neering for Food City said in a statement, Under the Energy Policy Act (EPAct) Sec-
merchandise more appealing, more comfort- The biggest expense was not replacement tion 179D, commercial property owners who
___
able to look at and more eye catching (www. lamps and ballasts, but sending contrac- make qualifying energy-reducing invest-
__________________________
lrc.rpi.edu/publicationDetails.asp?id=912). tors to the stores to begin with. Preventa- ments in new or existing locations can obtain
tive maintenance measures were costing tax deductions of up to $1.80/ft. The current
Recent case studies Food City more than $5 per door per year, or law is effective for projects completed by
Th ree recent installations of refrigerated
case lighting took place in grocers in differ-
ent parts of the world: the Jeronimo Martins
Group in Portugal, Sainsbury in the UK and
Food City in the US.
The Jernimo Martins Group was among
the first European retail companies to equip
its new stores entirely with LED lighting,
including the outdoor parking lots and gas
stations. The first installation took place in
2011 in its Recheio store in Torres Vedras,
a region north of Lisbon. For its refriger-
ated shelf lighting, Arquishelf luminaires
were designed with 56 Oslon SSL LEDs from
Osram Opto Semiconductors. Energy sav-
ings was estimated at 50% for the Recheio
facility. The all-LED lighting facility will be
used as a model for the chains other stores.
The second installation is scheduled to take
place in a store in Tavira, Portugal (www.
___
___________________
ledsmagazine.com/news/9/2/3). FIG. 7. Food City renovated 89 stores, claiming a $337,000 annual savings in energy
Sainsbury, a supermarket chain in the UK cost for lighting and refrigeration (photo courtesy of Food City and GE Lighting).

28 OCTOBER 2012 LEDsmagazine.com

_____________________
lighting | REFRIGERATED CASES
December 31, 2013.
Local utility rebates for refriger-
ated case lighting vary by state (see
www.dsireusa.org). One prerequisite
for accessing these rebates is that the
product chosen is listed in the qual-
ified product list of the DesignLights
Consortium.
Rebates can impact ROI consider-
ably. Rebates are provided on a per
door or per fi xture basis. For example,
utility provider Sacramento Munic-
ipal Utility District (SMUD) in Cali-
fornia offers a rebate of
$55 per door in ver-
tical cases. In a 5-door case, 6
fi xtures are used so the savings amounts
to $45 per fi xture. With occupancy sensors,
SMUD makes available a rebate of $85/door,
or $425 per 5-door freezer, which amounts to
$70 per fi xture.
Lithonias Pearson sees widespread inter-
est in occupancy sensing and dimming,
especially among stores that operate 24/7.
GEs Fowler commented that the customers
most interested in the technology are those
that pay the most for electricity. Retailers
who really watch their power usage will
adopt occupancy sensing to further reduce
costs. However, we also see that some retail-
ers have concerns about the impact of dim-
ming on brand image, she said.
As retailers worldwide evaluate and grad-
ually adopt occupancy sensing, the tech-
nology in the sensors continues to advance.
Whereas earlier sensors led to abrupt changes
in lighting levels, the newer sensors and pro-
gramming in LED fi xtures allows more grad-
ual changes in light level. We have what we
call follow-me dimming, where light lev-
els are boosted as a person approaches and
LINKS
Walmart, Walgreens and The Fresh Market among industry leaders in lighting efficiency
www.ledsmagazine.com/press/33495
Nualight introduces Zest, a world-first linear LED accent lighting system
www.ledsmagazine.com/products/35317
30 OCTOBER 2012
walks past the display case, said Ford. When
no person is detected for some period of time,
dimming the light levels by 50% will signifi-
cantly reduce energy cost.
Lifetime, maintenance and reliability
Maintenance savings and cooling savings
also contribute to ROI. The fluorescent tubes
in a freezer environment typically last only
6-12 months and the difference in heat gen-
erated between LED fi xtures and fluorescent
tubes can amount to 100 BTU per door. Most
of the LED fi xtures are rated for 50,000 hours
or five years. Maintenance costs will vary
by the size of the installation, but as we dis-
cussed with the Food City example, main-
tenance cost can be significant.
The other fac-
tor that gro-
cers and other retailers
evaluate closely, beyond ROI and
color quality, is the speed of installation
with refrigerated case lighting. Th is is a
very fast paced industry, so a retailer can
sometimes provide only 6-7 weeks notice
for a facility that wants installation within
3-6 months. You need a very flexible supply
chain to do that, said Kelly. He added that
while speedy installation is needed, so is
careful installation.
I think the major technical challenge is
not associated with the LED fi xtures them-
selves but the ease of installation it has to
do with the design of the peripherals, the
cabling, the LED driver, the robustness of
brackets/clips you use, said Kelly. By hav-
ing the flexibility in your fixture design to suit
any case interior profi le, you can adjust the
lighting before and after installation to create
the optimal impact. Thats becoming increas-
ing important, he said.
FIG. 8. The Zest accent luminaire
reduces energy use by 40% over
HID and features CRI of 95 (photo
courtesy of Nualight).
To ensure reliability, most man-
ufacturers are very select about the
LEDs they use, or they use in-house
LEDs. The LEDs are fully tested for
reliability under IES LM-79, then the
fi xtures are reliability tested under
IES LM-80.
Next steps for food retailers
The retrofit of fluorescent tubes to LED
lighting in refrigerated cases is deliver-
ing an energy savings of 60%. The next
generation coolers have been designed
with integrated LED lighting, and as
occupancy sensors improve it is
likely that dim-
ming will be used
to further reduce energy use.
Increasingly, retailers are looking to dif-
ferentiate their stores and spotlight spe-
cific foods or products. While the adoption
of LED lighting in refrigerated cases was
driven by energy savings and incentives,
the adoption of LED lighting throughout the
stores is more driven by the merchandising
effect of LED lighting.
The brighter LEDs available today are
increasing the chances that ambient LED
lighting can be used to bring out col-
ors and textures of produce and specialty
items. For example, the Zest accent lumi-
naire from Nualight (Fig. 8) has been specif-
ically designed for food retail environments
and features a CRI >90. The color tempera-
ture may be tuned via remote control from
2700K to 5000K to suit the display merchan-
dise allowing the retailer the flexibility of re-
configuring display layouts without needing
to change the light fi xture. The 8-ft model
produces 1600 lm at 30W power.
LEDsmagazine.com
 Fortimo LED Systems
for today, for tomorrow

Lets talk about high quality white LED accent lighting

With colour rendering levels over 90 and high R9 values, what about
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Fortimo LED SLM Gen3

Sandra Borba, Business Development Manager LED

__________________
conference report | THE LED SHOW

The LED Show conference spanned

components to lighting design
Presenters at The LED Show covered the full gamut of SSL design issues ranging from LED
component topics to advice for product specifiers and lighting designers, report MAURY WRIGHT and
LAURA PETERS.

S
olid-state lighting (SSL) is simply
a different beast than legacy light
sources. Presentations at The LED
Show in Las Vegas, NV made that fact per-
fectly clear as product developers and light-
ing designers were instructed in the sub-
tleties of LED sources, the complexities of
driver electronics, and the different ways in
which SSL should be applied. Exhibitors also
covered the entire supply chain from compo-
nents to end products (Fig. 1). Together the
exhibits and sessions were a good match for
the audience that in large part seemed rel-
atively new to LED technology. Still there
were informational nuggets for everyone as
we will report here.
The conference sessions at The LED Show
began with a focus on component manufac-
turers but Cree led off explaining that its the
system-level aspect of SSL design thats most FIG. 1. The LED Show exhibits drew a crowd.
important. Richie Richards, manager of
applications engineering at Cree presented the testing program to luminaires based on that comprise a lamp or luminaire. Outgas-
Quality SSL: What is it? About quality he Cree LEDs. And he said that Cree was will- sing that occurs during operation at tem-
said, When you see it you know it. In SSL its ing to share its testing techniques to help perature can cause failures such as yellow-
the same thing. He noted that LED quality move the industry forward. ing of optics and a significant reduction of
alone doesnt matter in a fi xture design. The lumen output. During TEMPO testing, Cree
entire system design must be optimized to System tests creates a test circuit board and exposes the
yield a quality product. Richards also discussed some examples of LEDs used in the product under test to the
Richards said concerns about poor qual- tests that Cree performs. For example, the chemicals present in other elements of the
ity products derailing the momentum of company performs thermal imaging on the design such as glues, seals, potting mate-
SSL was the factor that led Cree to create electrolytic capacitor in the driver electron- rials, and conformal coatings to fi nd prob-
the Thermal Electrical Mechanical Photo- ics of an SSL product under test, since that lematic interactions.
metric Optical (TEMPO) testing program capacitor is known as a primary source of The point to much of Richards presen-
that is offered to luminaire makers (www.___ failure in SSL products. Cree then provides tation is that industry standards such as
ledsmagazine.com/news/8/9/32). Rich- the luminaire designer with a projection of LM-79 and LM-80 dont ensure quality
ards unveiled a number of interesting facts the lifetime of that capacitor based on its products (Fig. 2). Cree believes TEMPO
about TEMPO. He said Cree hadnt limited specs and the condition under which it is can cover the additional areas of prod-
being operated. uct design that matter in terms of quality.
MAURY WRIGHT is the Editor and LAURA Cree has also stressed in the past that Other things TEMPO includes are a look at
PETERS is the Senior Technical Editor of LEDs product makers must understand the chemi- fl icker issues, solder quality, dimmer com-
Magazine. cal interactions between the varied elements patibility, and the ability of a design to

LEDsmagazine.com OCTOBER 2012 33

conference report | THE LED SHOW
withstand electrical spikes.
One other surprise in Richards talk was
his assertion that even large lighting com-
panies are using the TEMPO service despite
having their own testing equipment. Gener-
ally the assumption was that smaller compa-
nies without comprehensive labs would most
benefit from TEMPO. Presumably Crees test-
ing confi rms the products performance or
perhaps finds something the manufacturer
Silicon-based manufacturing, as opposed to
the use of sapphire substrates, could reduce
costs in a number of ways.
missed bringing value to organizations of all
sizes. Richards closed noting customer suc-
cesses, saying a South African lighting man-
ufacturer won a contract to supply 50,000
LED downlights to Kentucky Fried Chicken
restaurants after showing a TEMPO report
to the customer.
Bridgelux and cost
When Jason Posselt, vice president of chan-
nel marketing at Bridgelux, took the stage
the talk turned to LED costs (Fig. 3). He
asked rhetorically why LEDs arent every-
where and answered his question noting
high costs.
Posselt presented LED arrays as one way
to mitigate the cost issue. He used retail
applications as an example. Generally stores
want high-quality lights to highlight mer-
chandise. And as you move to the high end
of the retail market the demand can be for
very high-quality lights.
For such high-end applications, Bridge-
lux offers its Decor line of arrays that fea-
ture a color rendering index (CRI) of 97. The
company also has similar arrays in 80- and
90-CRI versions. Posselt said a company can
design one product and drop in the array
that matches customer requirements. The
lighting maker may sell a majority of the
80-CRI products but can supply the higher-
end versions when needed.
Still, LED component cost remains an
issue upon which everyone is focused even
though the LED or LEDs are rarely the most
expensive portion of an SSL product these
days. Posselt touted Bridgeluxs work on gal-
34 OCTOBER 2012
lium-nitride-on-silicon (GaN-on-Si) manu-
facturing as the ultimate path to lower cost.
Toshiba recently announced plans to man-
ufacture such LEDs this year using licensed
Bridgelux technology (www.ledsmagazine.
com/news/9/7/20).
LEDs on silicon
Silicon-based manufacturing, as opposed to
the use of sapphire substrates, could reduce
costs in a number of ways. The silicon wafers
cost less and are more widely available. But
its the automation of the back end of the
LED manufacturing process that is the key.
A move to silicon would take advantage of
automation from the IC industry.
Posselt suggested that anyone that had
visited both an LED fab and an IC-indus-
try fab would know the difference. About an
LED fab he said, It almost looks like childs
play in a garage versus high-volume semi-
conductor manufacturing. And he said
every LED maker was working on silicon
manufacturing whether they would admit
it or not.
Abdul Aslami, regional sales manager
with Nichia, followed Bridgelux and mainly
touted the scale of the company and the
breadth of its product line. Nichia is the larg-
est LED maker globally. Aslami said that the
company manufactures 2.2 billion LEDs per
month at its main plant in Japan.
But it was statements made that were
apparently directed at Bridgelux and Cree
that were most interesting. Despite Posselts
claim about all manufacturers researching
silicon substrates, Aslami said, We are not
investing money or time on LED GaN on sil-
icon. He said Nichia had investigated that
technology previously and concluded that
GaN on sapphire was optimum for LEDs
and lighting.
Aslami also said that Nichia would not
compete with its customers that make light-
ing products, by manufacturing its own SSL
products. Obviously Cree does so to some
extent with Cree Lighting. And other verti-
cally-integrated companies such as Osram
and Philips do as well.
LED source size
The final speaker from the component area
was Chuck DeMilo, director of product mar-
keting at Luminus Devices. DeMilo dis-
cussed the challenge of difficult retrofit lamp
applications such as replacing a 50W halo-
gen MR16 with LEDs. Quickly summarized,
the challenge is delivering more than 750
lm with tight beam control. Moreover you
are limited to 8-10W in power dissipation to
stick with a passive cooling scheme accord-
ing to DeMilo. He said ideally you would use
the smallest possible point source for such
an application, but unfortunately you need
a fairly large emitting area to generate the
required light output.
Luminus was founded around the con-
cept of making larger LED chips that in turn
can support higher current density and pro-
duce more lumens. But Luminus also makes
multi-die LED packages now that can be
What else is
required for Reliability: Photometric:
excellent SSL IES LM-80-08 IES LM-79-08
quality? & TM-21
Industry
standard testing
FIG. 2. LM-80, TM-21, and LM-79
are valuable industry standards, but
dont guarantee quality SSL products
according to Cree.
simpler to drive in an application such as
an MR16 driven from line voltage.
DeMilo said in the end that input volt-
age considerations may guide the choice of
LEDs. The company offers a 4-die LED that
has a forward voltage of 12V that is a bet-
ter fit for line-voltage applications. Alter-
natively, they offer a single-die LED with a
forward voltage of 3.1V that is a better fit
for 12V DC or transformed AC track light-
LEDsmagazine.com
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 conference report | THE LED SHOW

ing. Both products deliver 850 lm and a what he implied was a widespread percep-
CRI of 80. tion that SSL uptake was slow. He pointed
Still DeMilo warned of one other issue out that it took 18 years for electronic bal-
when you work with multi-die LEDs. He lasts to take over from magnetic ballasts
said, When you use multiple emitters in in fluorescent. He said the tipping point
a packaged LED, the source can get reim- came after 12 years. He said that LEDs have
aged out in your beam pattern. For more arrived at the tipping point in essentially
information on that topic, view our recent only four years.
_________
webcast on packaged LEDs (www.ledsmag-
________________
azine.com/features/9/8/3). Daylighting maximizes savings
But the recurring theme in Selanders talk
Controlling light was intelligent design. He focused heavily
Following the LED manufacturers, a num- on the use of daylighting. Daylighting has
ber of executives from lighting compa- the potential to provide savings when we
nies made presentations including John need it the most during the peak energy-
Selander, director of specification sales at use period in the afternoon. During a three
Acuity Brands. Selanders talk was on intel- hour period between 2:00 and 5:00 PM light-
ing and air condition-
ing can each account for
as much electricity as all
other elements of a com-
mercial setting combined
such as office equipment,
water heaters, refrigera-
tion and others. Indeed
lighting is the biggest
consumer at 31%. The
lighting community can
significantly reduce usage
starting with daylighting.
Selander had some
FIG. 3. Jason Posselt, vice president of channel marketing compelling stats. He said
at Bridgelux, discussed LED costs. office workers perform
10-25% better in a daylit
ligent digital lighting. Intended or not, the environment. Students have demonstrated
word intelligent both implied intelligence 20-26% faster progression in course work.
in lighting fi xtures and in the people who He said one study showed a 40% increase
design and install lighting. Slashing energy in retail sales with daylighting. And imple-
and improving lighting comes down to the mented properly the technique can provide
simple concept of putting the right level of a 40% reduction in energy.
light where it is needed and only where it is Of course even daylighting requires con-
needed according to Selander. He said, Use trols integrated into lighting products.
the right amount of light for the task. Light sensors are required to boost the
Often when we discuss control, we are artificial light levels as the sun wanes. And
talking about using sensors to control light Selander lamented the lack of controls in
levels and Selander did address that topic. commercial spaces in general, saying Most
But first and foremost you also need to con- buildings in North America dont have
trol the light distribution. LEDs present enough lighting controls. Indeed light-
an opportunity to do so, but not all fi xture ing controls lag other automated building
designers have learned how to tame the rela- controls such as heating ventilation and air
tively new sources. Selander said, LEDs are conditioning (HVAC) badly.
point sources and should be used as point Ultimately Selander believes all fi xtures
sources. He said that the optics design is will embed intelligence and communicate
critical in putting the light on task. wirelessly, but there are simpler avenues to
Selander also addressed the inaccuracy of energy savings in the short term. Occupancy

LEDsmagazine.com
_________________
 conference report | THE LED SHOW

Energy savings (%)

Maximum
100
Average
90 Minimum

80
75
70

60 60 60 60 60
56
50 48
45 45 45
40 40 40
35
30 30 30
23 21
20

10
0
m ria m m m ay ks en te ge ed te ell m m es ea
k roo afete e roo y roo nasiu allw stac e op priva gara ition priva tairw e roo ssroo e aisl en ar
rea C renc Cop ym H ary ffic ce g r t S g l a s p
B G Lib
r O Offi arkin m pa troom ra /c
Sto oom areh ouse
ou o
nfe P roo Res
Co st g r W reh
e n a
R ini W
Tra

FIG. 4. Energy savings from the use of occupancy sensors can range to 80%.

sensors are a primary option for savings. Fig.
4 shows the potential range of savings attrib-
utable to occupancy sensors in a number of
specific areas.
Selander also discussed the concept of
vacancy sensors. Basically an occupancy sen-
sor can wait through a short delay before turn-
ing lights on when someone enters a room.
In an office setting, if a worker steps in and
retrieves a paper from their desk and exits
immediately, then the lights never come on.
Simple SSL installation
Turning to SSL retrofits, and commercial
and industrial spaces in the US are a huge
potential market, Kurt Vogel, the director
of product development of Acuity Brands,
addressed the growing trend of retrofit SSL
products than can be installed into exist-
ing fluorescent troffer frames. Such a ret-
rofit can be accomplished from below with
the dust in the ceiling left undisturbed.
End users can reduce costs, achieve sus-
tainability goals and reap the benefits of
LED lighting without disrupting the work-
place, said Vogel.
LED retrofit kits provided by Lithonia and
other manufacturers can reduce the cost,
installation time and waste associated with
commercial lighting upgrades. Beyond that,
the quality of the light can be improved dra-
matically, from a so-called parabolic light
pattern to more volumetric lighting that
truly fi lls the room.
Vogel highlighted results from a recent
DOE report that stated that there are roughly
1 billion T12 fluorescent tubes installed in
buildings in the US, and half of those can be
found in commercial spaces. The replacement
of these tubes with T8 or T8-equivalent prod-
ucts represents a potential $4 billion savings
annually alone, or the power generated by 15
coal-powered generation plants.
Recent legislation that phases out instal-
lation of T12 fluorescent tubes in the US
began in July and is providing a kick start
to the commercial LED lighting market,
according to Vogel. In the US, he stated
that fluorescent lighting consumes approx-
imately 250 TWh of electricity a year.
In one example, Vogel showed a typical
conference room with several 24-ft fluores-
cent troffers that were upgraded using LED
retrofit kits. Each fluorescent troffer in the
room contained three lamps and two bal-
lasts. The kit contains three elements: the
end brackets, light engine and trim. Using
the existing wiring and housing, the new
LED lighting provided an average of 20 fc
less at the task surface but the distribution
of light in the room was clearly superior. The
energy savings was 59W per fi xture.
Save the Titanic
The closing act at The LED Show featured
well-known lighting designer Chip Israel

LEDsmagazine.com
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 conference report | THE LED SHOW

(www.ledsmagazine.com/features/8/2/6) trum can become a data communications

of Lighting Design Alliance and Terrence medium. Walsh also mentioned adaptive
(Terry) Walsh (www.ledsmagazine.com/ controls and even biochemical sensing as
___________ president of lighting
features/8/3/12), applications. The point is that once you put
manufacturer Tempo Industries an early intelligence into fi xtures you can ask that
player in LED lighting. Both are outspo- microprocessor to do other things. And the
ken and knowledgeable and
didnt disappoint The LED
Show attendees.
Walsh (Fig. 5) boldly kicked
off a discussion of the transi-
tion to SSL when he said that
he tells lighting designers,
If you spend any time work-
ing on fluorescent, HID, mer-
cury vapor, or other legacy
sources, all you are doing is
reorganizing the deck chairs
on the Titanic.
The presentation was enti-
tled The future of lighting
and clearly Walsh believes that FIG. 5. Terrence Walsh of Tempo industries focused on
future is centered on LEDs. SSL as the future of lighting.
But with that transition must
come major changes in mindset toward light- transition to electronics lighting will bring
ing. Walsh said we all must adapt to thinking a host of new players into the lighting world
about lighting as an appliance as opposed to according to Walsh.
as a disposable commodity. That change in Israel, meanwhile took his typically mea-
mindset will help justify the higher upfront sured approach to addressing SSL pointing
cost of SSL and better match to the longer life out its advantages and pitfalls. He essen-
of LED-based products. tially agreed with Walsh on the subject
Walsh allows that there will be a period of retrofit lamps saying that LEDs in old
of time where SSL retrofit lamps and tubes light fi xtures arent good. He also said, For
have a place in the transition. But he pre- the last 30 years the lighting industry has
dicted what he calls socket saturation to worked hard to eliminate glare. His point
occur in about five years with most all SSL was that glare is an issue with LEDs and
products being purpose designed and built must be dealt with by product developers
going forward. The lamp industry certainly and lighting designers.
has issues as more than 3000 companies The issue of light control is a major one
are making LED lamps according to Walsh. for Israel. You have to put light where work-
And he noted many reports of product fail- ers need it. And he said the industry must
ures within 100 hours. He said, The lighting be careful when discussing energy savings
industry has its own Yugos. with lighting. He said workers will bring a
light from home and plug it in at their desk
Energy savings to be free if they dont get the light they need. And its
The driver today for the SSL transition is the total power load that matters.
energy savings as we all know. But Walsh Like Walsh, Israel sees a bright futures
said, Energy wont be the prime driver in a for capabilities unique to LEDs. He cited
few years. It will be automatic. He likened tunable color sources as an exciting area
getting energy savings with lighting to get- and a technology that can enhance our
ting air conditioning on a car. wellbeing. Moreover, Israel brought the
Its the unintended consequences of LED theme that started the conference full
lighting that may ultimately prove to be the circle discussing lighting as a system. He
most exciting according to Walsh. It has said, If any single part of the system fails,
been widely reported that the light spec- it all fails.

LEDsmagazine.com
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technology | COLOR SCIENCE

Understand color science to maximize

success with LEDs part 3
By understanding color science and the potential of color mixing with LEDs with multiple CCTs you
can design an SSL lamp or luminaire with excellent lumen and color maintenance, CRI, and efficacy,
explains GEORGE KELLY.

L
ED-based lighting is certainly a growth
industry, but also one in which we are
still learning how to employ solid-state
lighting (SSL) technology to deliver optimal
light quality along with the expected bene-
fits of lower power consumption. If you under-
stand color science, and the capabilities of
mixing LED color, however, you can design
products that deliver on the seemingly oppos-
ing goals of quality and efficiency.
In the first article of this series we estab-
lished three foundational principles of color
vision: 1) The relative response of the three
ent color temperature white LEDs and from
colored LEDs to achieve results not possible
with white LEDs of the same color tempera-
ture alone. In the first example we will show
how to make a white LED source with a tun-
able color temperature. In the second exam-
ple we will improve upon this type of source
by adding a third non-white LED.
CCT tunable lamp
Unlike both sunlight and incandescent
light bulbs, LEDs have a fi xed color temper-
ature. To make an LED source that mim-
doesnt discriminate colors that closely so as
long as we are close to the Planckian locus the
results will be satisfactory for all but the most
demanding applications.
The issue to address is how we determine
the relative brightness of each LED that is
required to move along the line between
6500K and 2700K. The problem is trivial if we
simply want to have a control knob that var-
ies the color temperature by simply increas-
ing the brightness of one LED while decreas-
0.9

types of cone cells in the retina is sufficient ics sunlight as it changes color temperature 0.8
to explain color vision, 2) Metamerism which throughout the day or an incandescent bulb 0.7
is a direct result of the first principle and 3) as it is dimmed, we have to mix together the
Color can be characterized by numerous sets light from two or more different color tem- 0.6

of color-matching functions, all of which are
linear transformations of each other.
In the second article we used these princi-
ples to explain the origins and uses of the CIE
Color Diagram including predicting the color
coordinates in the CIE Color Diagram for
mixtures of colors. We also discussed the ori-
gins of the Planckian locus, a curve through
the center of the CIE Diagram which plots
the color coordinates of a particular type of
white light sources known as blackbody radi-
ators. Blackbody radiators emit light due to
their high temperature. The location along
this curve depends on the temperature of the
object. From this we explained why LED man-
ufacturers design their white LEDs to have
color coordinates that fall as close as possi-
ble to the Planckian locus.
In this article we build upon this knowl-
edge to show how to design LED illumina-
tion devices that mix the light from differ-
GEORGE KELLY is an LED Technical Specialist
at Avnet Electronics Marketing.
perature LEDs. We learned in the previous 0.5
article that the chromaticity coordinates of y 2700K
0.4
a mixture of two colors will fall on a line in 6500K
the CIE Diagram between the chromaticity 0.3
x, y coordinates of mixture
coordinates of the two colors being mixed. 0.2 will fall along this line
Since the Planckian locus is a curve and
0.1
not a straight line, a two LED mix will only
0.0
approximate the Planckian locus for a rel- 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
atively short span of the locus. Fortunately x
the region from 2700K to 6500K can be FIG. 1. The chromaticity coordinates of
approximated quite well with a straight line the mixture of light from a 6500K LED
between x = 0.464, y = 0.409 (~2700 K) and x and a 2700K LED.
= 0.312, y = 0.323 (~6500 K) (Fig. 1).
If we wanted to exactly follow the Planck- ing the brightness of the other LED as the
ian locus we would need to mix in a third control knob is turned. If, on the other hand,
LED so that the gamut of the three LEDs we want to choose a specific target color
would completely encompass the Planckian temperature, then the problem gets more
locus from 2700K to 6500K. A third LED at x complicated.
= 0.35, y = 0.4 added to the mix would expand First we need to determine the chromatic-
the gamut enough to fully encompass the ity coordinates of the target color tempera-
Planckian locus over the desired range (Fig. ture. There are two ways to do this: 1) Cre-
2). In practice this approach is not warranted, ate a look up table using Plancks Law, or 2)
because we cannot buy any LEDs with those Approximate the Planckian locus with two
precise chromaticity coordinates. The eye polynomials, one for x as a function of tem-

LEDsmagazine.com OCTOBER 2012 43

technology | COLOR SCIENCE
perature, T and the other for y as a function 0.9
of x. This is possible because the x value of the 0.8
Planckian locus decreases monotonically as a
0.7
function of T. In other words there is only one
value of x for every value of T on the Planck- 0.6
ian locus. This is not the case for y. Even so
0.5 x = 0.35
y Gamut of 3 y = 0.4
there is only one value of y for every value of x LED mixture
0.4
along the Planckian locus. The polynomials 2700K
6500K
below were fit to the Planckian locus in using 0.3
a curve fitting function in a spreadsheet. 0.2
0.1
x(T) = -8.4254x 10 -13T3 +2.0203 x 10 -8T2
0.0
-1.7034 x 10 -4T + 0.79556 0.0 0.1 0.2 0.3 0.4 0.5
x
y(x) = -2.2985x2 + 2.3488x - 0.186
FIG. 2. The chromaticity coordinates of
the mixture of light from a 6500K LED, a
These approximations are accurate over 2700K LED and a 3rd off-white LED.
a CCT range of 1700K to 10,000K to within a
distance of less than 0.003 in the x-y plane, be found for a new T, the calculation will
except at the extreme end of the ends where involve two multiplication, two addition,
the error grows to 0.01. While these equations and one division operations. This is not too
look rather complicated, they can actually be difficult to perform in a microcontroller,
simplified to run on a microcontroller. but could easily be converted into a look-up
Once we have the chromaticity coor- table to simplify the task.
dinates of the desired color temperature,
we need to calculate the relative bright- Adapting to LEDs
ness of the two sources required to achieve Th is all looks rather straightforward until
these chromaticity coordinates. In part 2 we consider that it is impossible to buy LEDs
__________________
of this series (www.ledsmagazine.com/fea- with exact chromaticity coordinates. LED
________ we presented two equations
tures/9/7/14) manufacturers sell LEDs in chromaticity
for finding the chromaticity coordinates of bins and generally will not sell just one bin,
a mixture of two LEDs given their relative but a grouping of bins. Th is inherent vari-
brightness k1 and k 2 and the x, y coordinates ability in the chromaticity coordinates of the
of each LED. The equation to find the x coor- two LEDs used to create the new mixture
dinate of the mixture, is: will result in a corresponding variability in
the chromaticity coordinates of the mixture.
x1 x2 k1 k2
xm = (k1 y1 + k2 y2 )/( y1 + y2 ) We can use what we have learned to date to
0.50
We also can apply the condition that the
relative brightness of each LED sums to 1
0.45
resulting in: Upper boundary
k1 + k2 = 1
0.40 Planckian Locus
If we treat these two equations as a lin- Lower boundary
y 0.35
ear system, then we can solve for k 1 and k 2
given x m and the chromaticity coordinates
0.30 6500K Bounds of a mixture with
of the two LEDs. bin a target CCT of 5000K
k1 = (x2y1 - y1xm) / [(y2 - y1)xm - (x1y2 - x2y1)]
0.25
k2 = 1-k1
0.20
The majority of the terms in the first equa- 0.3 0.4
x
tions can be calculated in advance. Only the
terms that include x m need to be calculated FIG. 3. The central region of the CIE
for a new target color temperature, T. Th is diagram and the bounds of a two-white-
means that for each time k1 and k 2 need to LED mix on the diagram.
44 OCTOBER 2012
0.9
0.8
0.7
0.6
EQW bins
0.5 CCT = 2700K
y
0.4
CCT = 6500K
0.3
0.2 Cool white bins Amber LED bins
0.1
0.0
0.6 0.7 0.8 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
FIG. 4. A three LED mixture, including cool
white, the Osram EQ-White, and an Osram
amber with a triangle representing the
minimum gamut of the mixture.
put bounds on this error.
We know that the coordinates of the mix-
ture will fall on a line between the coordi-
nates of the two LEDs so an upper and lower
bound of the coordinates of the mixture can
be established by drawing lines between the
upper- and lower-bin boundaries of the two
LEDs (see Fig. 3). The boundaries on the left
and right can be estimated for a particular
color temperature, by solving for k1 and k 2
using the coordinates of the center points
of the bins and then solving for the coordi-
nates of the mixture (x m , y m) using the verti-
ces of the LED bin boundaries. In the exam-
ple in Fig. 3 the left and right boundaries are
drawn in for a target CCT of 5000K. The left
and right boundaries in this case represent
CCTs of approximately 5150K and 4880K.
If this degree of error is unacceptable there
are two basic ways to reduce the error. One
way is to calibrate each light during manufac-
2700K bin
turing by measuring the exact chromaticity
coordinates of the LEDs in the light and then
storing those values in a non-volatile memory
for use in calculating k1 and k 2. This method
is obviously expensive and it cannot correct
for shifts in the LEDs chromaticity coordi-
nates as the LEDs heat up or age. The second
approach is to add a color sensor and use it
in a feedback loop to calculate the relative
brightness of each LED to achieve the desired
0.5 mixture. In the next example we will explore
this approach while adding a third LED.
Three LED CCT tunable white lamp
Adding a color sensor for feedback can solve
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___________________
technology | COLOR SCIENCE

Relative sensitivity Relative sensitivity

1.0
1.8

0.8
1.3
0.6

0.8
0.4

0.2 0.3

0.0 -0.2
400 450 500 550 600 650 700 400 450 500 550 600 650 700
Wavelength (nm) Wavelength (nm)

FIG. 5. The wavelength sensitivity curves of a typical red, green FIG. 6. Transformed wavelength sensitivity curves superimposed
and blue color sensor. on the CIE color matching functions, x(), y(), and z().

a number of problems. First of all there is no
need for matching chromaticity bins of the
cool and warm white LED pairs. In fact the use
of feedback from an accurate color sensor can
reduce the chromaticity error of the mixture
to a fraction of the size of the LEDs chromatic-
ity bins themselves. A sensor can also compen-
sate for changes in the chromaticity coordi-
nates of the LEDs as they warm up on startup
or as they age throughout their lifetime.
Adding a third LED to the mixture pro-
vides further flexibility especially if the
chromaticity coordinates of the third LED
are not collinear with the coordinates of the
other two LEDs. The triangle formed by the
chromaticity coordinates of the three LEDs
envelops the gamut of the mixture of the
three LEDs. Any coordinate within this tri-
angle can be achieved with the correct rela-
tive brightness of the three LEDs.
In this example we will use Osram's Bril-
liant Mix technology. Brilliant Mix is a two
LED mixture of an amber LED and a greenish
white LED Osram calls EQ White, to achieve
a high luminous efficacy white mixture at
warm white CCTs and with excellent color
rendering index (CRI). In conventional white
LEDs, the luminous efficacy of the LED drops
as the color temperature is reduced. The rea-
son for this is that the phosphors required to
produce a spectral power distribution (SPD)
with high power on the red end of the spec-
trum required for a lower color temperature
also produce red light at wavelengths above
650 nm where the eyes sensitivity falls off
dramatically.
Brilliant Mix solves this dilemma by using
an amber LED with a peak wavelength of 625
nm to increase the SPD of the mixture at
the red end of the spectrum without requir-
ing an inefficient phosphor which produces
excess power above 650 nm. The EQ White
LEDs use a phosphor that peaks around 550
nm, which also happens to be very near the
peak of the V() curve so the EQ White LEDs
have a very high luminous efficacy. With the
addition of a third cool white LED to the red
and EQ White LEDs of Brilliant Mix a CCT
tunable white lamp with high luminous effi-
cacy and high CRI can be achieved (see the
gamut of the three LEDs in Fig. 4).

___________________________________

______________________

46 OCTOBER 2012 LEDsmagazine.com

______________
technology | COLOR SCIENCE
Color sensors adds fidelity
There are at least two ways to use a color sensor to control the
chromaticity coordinates of the mixture. Th e fi rst method is to
measure the exact chromaticity coordinates of each LED and then
compute the brightness of each LED to achieve the desired chro-
maticity coordinates. To measure the chromaticity of each LED
independently means that each LED must be on while the other
two are off. The issue here is how to do this without it being notice-
able. Th is could be done at startup, but then any shift in color as
the LEDs come up to temperature will not be taken to account. It
could also be done periodically as the light is on by cycling through
the LEDs in rapid succession. If done quickly enough the eye will
average the colors together and it will not be noticeable that the
individual LEDs are on one at a time. Th is cycling only needs to
be done once every 10 seconds or so minimizing the chance of the
cycling being noticed.
The second method avoids this complexity by simply measuring
the chromaticity coordinates of the mixture and using a feedback
loop to zero out any error between the chromaticity coordinates of
the actual and target colors.
In either method we require a color sensor that can be calibrated
to output accurate color measurements. There are several good color
sensors to choose from. We also have a choice of working in CIE chro-
maticity coordinates or in tristimulus values. The calculation of the
relative brightness of each LED is simpler mathematically using tri-
stimulus values, but then we need to convert the target chromaticity
___
coordinates to XYZ tristimulus vales (see part 1 of this series, www.
ledsmagazine.com/features/9/5/4, for an explanation on converting
from chromaticity coordinates to tristimulus values).
One solution is to use a color sensor that outputs tristimulus val-
ues directly such as MAZeTs MTCSiCS color sensor. There are also
several RGB sensors commercially available, which have three differ-
ent sensor types that roughly correlate to red, green and blue. Exam-
_____
48 OCTOBER 2012
ples include Maxims MAX4406/MAX44008 or Intersils ISL29120.
These sensors use absorption fi lters similar to the ones used in the
CCD and CMOS image sensor of digital cameras.
To understand how to calibrate an RGB sensor to effectively out-
put tristimulus values, we can make use of the third fundamental
principle of color science discussed in this series that all color-
matching functions are linear transformations of each other. The
CIE color-matching functions from which we obtain the CIE XYZ
tristimulus values are just one such color-matching function. If the
wavelength sensitivity curves of an RGB color sensor just happen
to be color-matching functions, then a simple linear transforma-
tion will convert these curves to the CIE color-matching functions.
Applying such a transformation to convert the RGB output values
of a color sensor to XYZ tristimulus values is equivalent mathemat-
ically to transforming the wavelength sensitivity curves of the sen-
sor into the CIE color-matching functions.
While it is a theoretical possibility that the wavelength sensitivity
curves of any given RGB sensors are actually color-matching func-
tions, the chances of this being the case are practically zero. For-
tunately, the wavelength sensitivity curves only need to be close to
true color-matching functions to be useful for our purposes. One
way to find out how close the RGB sensitivity curves of a particular
color sensor are to a true color-matching function, is to find the lin-
ear transformation which when applied to the RGB wavelength sen-
sitivity curves results in the closest match possible to the CIE color-
matching functions.
Mathematically finding such a transformation is simpler than you
might think. Well walk through how this is done for a hypothetical
color sensor with RGB wavelength sensitivity curves typical of the
sensors that are commercially available (Fig. 5). In this example we
will use a transformation that uses the R,G,B outputs plus higher
order terms, RxG , GxB and RxB . In this case the resulting
transformation is:
LEDsmagazine.com
 technology | COLOR SCIENCE

R
G

[][
X M11 M12 M13 M14 M15 M16
Y = M21 M22 M23 M24 M25 M26
Z M31 M32 M33 M34 M36 M36 ] B
RG
GB
RB

We can estimate the individual coefficients of the transformation matrix, M by finding a

matrix that transforms the spectral sensitivity curves of the sensor, R(), G(), B(), R()G()
, G()B() , R()B() into the CIE color matching functions x- (), (), and z(): -

R 1 R 2 R N
x- 1x- 2 x- N G1 G2...GN

[ ][
z-1 z-2 z-N ]
M11 M12 M13 M14 M15 M16
y- 1y- 2 ... y- N = M21 M22 M23 M24 M25 M26
M31 M32 M33 M34 M36 M36
B1 B2 BN
RG1 RG2 RGN
GB1 GB2... GBN
RB1 RB2 RBN
The first matrix is a 3N matrix where N is the number of wavelength samples supplied
of the x- (), (), and z- () color matching functions. Likewise the last equation on the right
hand side is an N3 matrix where the wavelength sensitivity curves are also represented
with N samples.
To solve for the transformation matrix, we first represent each matrix in the above equa-
tion with xyz, M and RGB respectively. Reversing the left and right hand sides of the matrix
equation gives,
M RGB = xyz
Multiplying both sides by the transpose of RGB results in,
M RGB RGBT = xyzRGBT
Further multiplying both sides by the inverse of RGB, by its RGB transpose, RGBT gives
an equation for M.
M = xyz RGBT (RGB RGBT) -1
Calculating M for our example color sensor (Fig. 5) results in:

M =
[ 1.368 0.887 1.241 -2.175 0.711 -4.959
0.144 1.228 0.450 -0.559 0.310 -2.144
5.458 0.996 0.178 -5.027 -0.561 -0.127 ]
Using M to transform the sensors wavelength sensitivity curves into the CIE color match-
ing functions gives interesting results (Fig. 6). While the match is far from perfect, the trans-
formed curves match the CIE color matching functions reasonably well. The resulting error in
tristimulus values for a typical 5000K LED is -0.005 in x and -0.01 in y.
A calibrated color sensor is the last piece in the puzzle. Given a target color tempera-
ture, the x and y color coordinates can be calculated and then converted to target tristim-
ulus values. The current tristimulus values of the three LEDs can be measured with the
calibrated color sensor and then the relative brightness of each LED required to achieve
the target tristimulus values is just the weighted sum of the measured tristimulus val-
ues of the three LEDs that match the target tristimulus values. The brightness of each
LED can then be adjusted using either pulse width modulation (PWM) or by adjusting
the forward current of the LEDs. Typically PWM is superior to using forward current to
control LED brightness, because the LEDs output is not linear with current. In this case
though, the color sensor is giving continuous feedback of the actual brightness of each
LED and the feedback loop will null out any error caused by using forward current to set
LED brightness.
While these two approaches to color mixing outlined in this article add complexity and _____________

cost to an LED product, in the right application this added expense can be worth it. The use _____________

of multiple white and colored LEDs to create LED light sources with tunable color charac-
teristics combined with feedback from color sensors opens up new possibilities while simul-
taneously improving color accuracy.

LEDsmagazine.com OCTOBER 2012 49

____________
indooor | INDUSTRIAL LIGHTING

Textile and rubber manufacturer

installs LED high-bay lighting
A major manufacturer of floor mats converts a rubber manufacturing plant to LED lighting, reducing
energy use by 650 kWh per day and improving the light quality, reports MAURY WRIGHT.

I
ndustrial lighting promises to be one of
the next market segments in which LED-
based solid-state lighting (SSL) begins
to displace legacy HID sources and fluo-
rescent lighting. High up-front costs have
limited the adoption rate of SSL in such
applications. But factory owners are begin-
ning to grasp the advantages of LEDs, and
realize that sometimes having the lights
off is a good thing for the bottom line. A
Georgia-based textile manufacturer in the
US southeast recently converted one of its
manufacturing plants to LED lighting, and
positive results in energy consumption and
projected maintenance costs led the com-
pany to immediately begin a retrofi t of a
second plant.
LED lighting has certainly succeeded
broadly in many applications including
street lights. In the industrial space, the FIG. 1. LED lights uniformly light the manufacturing area in the Mountville Rubber
success has come primarily in two areas plant after the retrofit.
refrigerated facilities and warehouses.
Indeed the technology is regularly used cations. In factories with workers spread sale into other applications such as insu-
in refrigerated warehouses where the fact around a manufacturing f loor, there is lation for electrical wiring and boot soles.
that LEDs dont radiate heat is a good thing often less of a chance to leverage dimming, Mountville president David Hart knew
for the refrigeration system. And the ware- because the workers need the lights. More- that the company needed to retrofit the
house angle is important because workers over, some business owners simply have a metal halide (MH) lamps located in a num-
are only sporadically present in specific mindset of wanting the lights on. Custom- ber of the companys plants. The old lamps
areas of a warehouse, so such installations ers visiting a well-lit factory may perceive required regular maintenance and the light
can take full advantage of the dimming the lights positively thinking the factory quality needed to be improved. But he was
capabilities of LEDs based on occupancy is busy, and may perceive darkened areas initially skeptical of LEDs because of the
sensors or networked controls. In fact, negatively. But manufacturers such as high up-front costs. He also wasnt sure his
network lighting system specialist Digital Mountville Mills are willing to challenge operation could leverage dimming.
Lumens has reported customers achiev- those perceptions. As SSL prices began to drop, however,
ing 90% energy savings in cold-warehouse Hart decided to install LED lights in one of
applications (www. ledsmagazine.com/ Industrial and manufacturing the Mountville Rubber plants including a
news/8/1/24).
________ Mountville Mills is home-based in manufacturing area and a warehouse (Fig.
The case for LEDs isnt quite so clear in LaGrange, GA and is the leading manufac- 1). He became convinced that dimming
the broader segment of industrial appli- turer of floor mats in North America. The would boost savings in the warehouse area,
corporation also operates the Mountville and that his own management team and
MAURY WRIGHT is the Editor of LEDs Rubber Company that makes rubber used visiting customers would soon realize that
Magazine.. for the backing on the floor mats and for sustainable, energy-saving practices must

LEDsmagazine.com OCTOBER 2012 51

indoor | INDUSTRIAL LIGHTING

FIG. 2. Lithonia Lighting offers the sure of the aggre-

I-Beam LED high-bay luminaire in 9000- gate savings attrib-
to 24,000-lm models. utable to the lights,
because the lighting
become the norm rather than the excep- is on the same power meter
tion. Hart said, You have to adopt a with office lighting, the office
new mindset and see dark areas of heating ventilation, and air condition-
a facility as a positive thing for ing (HVAC) system, and office equipment.
the business. But comparing the month of August from
The rubber-plant instal- 2011 with the month of August from 2012,
lation included 20,000 ft Bud Paulk, pres- Paulk said electricity usage was down 39%.
of manufacturing space ident of Mountville Clearly the specific percentage of savings
and 60,000 ft of warehouse space. Rubber, says he believes strictly relative to plant lighting is greater.
The facility houses more than 50 workers that the LEDs provide 10-15% better light in The near-term net for Mountville Mills is
and produces 15 million pounds of rubber terms of uniformity and average brightness a savings of $1995 per month. Paulk and his
annually. (Fig 6). In the manufacturing area the light electrical crew are still experimenting with
level is now above 25 fc in most areas. occupancy sensors and light control. The
Replacement fixtures company purchased the IBL fi xtures with an
Prior to the retrofit, the manufacturing Electrical savings occupancy sensor on each fi xture. Initially,
area was lit with 30 400W MH fi xtures, and The baseline savings attributable to the LED the electricians set the lights to remain lit
the warehouse was lit with 99 400W MH lights is substantial. Paulk said the company for lengthy times such as 15-30 minutes once
fi xtures. Mountville engaged with Acuity
Brands Lithonia Lighting via local dis-
tributor Mayer Electric Supply to contem-
plate the retrofit. The Lithonia team rec-
ommended the LED version of the I-Beam
high-bay fi xture, called I-Beam LED or IBL,
that Lithonia announced early this year
(Figs. 2 and 3).
Johnny Brawner of Mayer said that ini-
tially the team considered a one-for-one fi x-
ture replacement using the 18,000-lm, 213W
version of the IBL. The product comes in
9000-, 12,000-, 18,000-, and 24,000-lm mod-
els. Ultimately, however, the team decided
that it could reduce the fi xture count by
moving to the 24,000-lm, 262W version
according to Brawner.
The goal was providing a minimum of 20
fc of lighting at the task level in the man-
ufacturing area, and 15-20 fc in the ware-
house when the lights were on. The MH
lights had delivered upwards of 50 fc directly FIG. 3. Mountville installed the I-Beam LED fi xtures without secondary optics such as
under each fi xture, but the levels dropped a diffuser lens.
below the 15-fc level in the middle ground
between two lights. The IBL fi xtures would measured the power consumption of the a sensor was triggered. Having gained com-
be spaced further apart but the team tested existing MH lights at 458W with the ballast. fort with the instant-on LEDs, Paulks crew
a fi xture and found the uniform light dis- Moreover, he said they measured the LED is transitioning to on-time periods as short
tribution could support the greater spacing. fi xtures at 286W. Paulk said the numbers are as 30 seconds.
Ultimately Mountville installed 25 IBL slightly higher than expected for both types Paulk commented that he walked into
luminaires in the manufacturing area and of lights because the input voltage is higher the warehouse one weekday morning and
54 in the warehouse a 40% reduction in than typical due to some specific equipment was shocked that most of the lights were
fi xture count. Figs. 4 and 5 show the ware- requirements in the factory. out on a workday, and for a moment slipped
house area before and after the retrofit. The company doesnt have an exact mea- into the old mindset that no one was busy

52 OCTOBER 2012 LEDsmagazine.com

______________
indoor | INDUSTRIAL LIGHTING
FIG. 4. Metal-halide lamps lit the warehouse area before the
retrofit.
working. Hart said that despite his initial
doubts, that 20% of the lights in the plant
are off on average during the main shift
and even more are off during night shifts.
They clearly expect to see more incremen-
tal reductions in energy usage attributable
to occupancy-based controls.
Costs and payback
Before embarking on the project, Mountville
analyzed the cost of the project and the
expected payback. The company used its
own in-house electricians to install the lights,
although they did account for that cost in
FIG. 6. Taken during the retrofi t process, you can see an LED luminaire in the
foreground with metal halide lights behind.
54 OCTOBER 2012
FIG. 5. The LED luminaires provide what Mountvilles
management team and workers consider more uniform light.
their analysis including the need to rent a
hydraulic lift for a month. They based the pro-
jection on an electrical cost of $0.10/kWh. The
expectation was that the project would pay-
back in 2.2 years.
The cost analysis was based on fi xture
costs at a little under $800 including the
occupancy sensor on each that is a $100
option. But electricity usage is lower than
Mountville expected, and their initial analy-
sis didnt take tax credits into account. Ulti-
mately the company could realize payback
nearer to a one year time frame.
As for the lighting, Paulk says that the
company has received only positive com-
ments from its workers that enjoy the
brighter and more uniform lighting. Visiting
the factory, its easy to spot the one problem
that plagues many SSL installations glare.
You can see that in some of the pictures pre-
sented here. The IBL fi xtures are very bright.
But in the Mountville application, the lights
are mounted so high that realistically glare
isnt an issue unless you look for it.
The Lithonia team, recommended that
Mountville install the IBL luminaires with-
out any secondary lens to maximize light
output. Lithonia does offer options for dif-
fusing lenses that can reduce glare.
Next steps
The installation in the rubber plant was just
completed in early July. But the success with
that project has prompted Mountville to
immediately begin a second retrofit. In this
instance, the company is upgrading their
flagship corporate headquarters plant that
measures 225,000 ft.
The decision was made easier in part by
the continual drop in SSL fi xture pricing.
Indeed Mountville is buying the same IBL
fi xtures but the price has dropped 6-7% in
just months. Clearly that rate of change
wont continue, but its indicative of how
rapidly LED lighting is maturing.
Meanwhile the retrofit in the second
Mountville plant where they manufacture
carpet, bind the rubber backing to the car-
pet, and cut the mats to size continues. In
this case the company will replace 418 MH
fi xtures with 206 IBL luminaires.
LEDsmagazine.com
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materials | SILICONE

Moldable optical silicones enable

LED lamps and luminaire designs
Silicone materials can withstand high heat and help deliver higher lumen density in SSL product
designs while simplifying the manufacturing process and enabling more complex architectures,
explains HUGO DA SILVA .

M
oldable silicones are emerging as a
viable option in LED-based prod-
uct designs for use as secondary
optics, light pipes, light guides, and other
optical components. Indeed new formula-
tions designed specifically for solid-state
lighting offer the ability to withstand high
temperatures associated with the LED semi-
conductor junction with no optical degrada-
tion. The material can also be molded into
complex shapes offering great flexibility to
the product developer.
The global lighting market is on the verge
of a transformation as LEDs increasingly
replace conventional light sources. Accord-
ing to analysts at research firm McKinsey &
Company, the market for LED lighting will
explode at 30% per annum to exceed $81 bil- FIG. 1. Moldable silicones enabled a design by LEDiL, a leading optics supplier, to
lion by 2020, when it will represent close to incorporate secondary optics that integrate dual functions the optics shape the
60% of the overall lighting market. light and seal the electronics against water ingress.
Such projections are supported by the
accelerating adoption of LED technology higher lumen density and power, physics will its early-generation designs and materials.
in more and more general lighting applica- demand they operate at higher temperatures In response, the industry is exploring new
tions, ranging from low-power, low-lumen even as lamp and luminaire designers seek materials, such as silicones that, while less
fixtures like downlight replacements to reduce the number of LEDs, or pack the familiar in LED applications, bring a rich
where LEDs are increasingly replacing low LEDs closer in order to develop sources that history of proven performance in dozens of
power compact fluorescent lamps and halo- are comparable or smaller in size than pre- other industries, including advanced elec-
gens to more challenging applications like vious generation devices. tronics, automotive and communications.
street lights, industrial lighting, office light- At the same time, LED designers are inno- Silicones address several of the challenges
ing, high power halogens or illumination of vating modules, lamps and luminaires that posed by next-generation LED designs,
sport venues. As LED-based light sources integrate multiple functions into fewer parts including the ability to withstand higher
further penetrate applications that demand (Fig. 1), or that incorporate smaller or more temperatures, support higher lumen den-
complicated features. LED manufacturers sity, enhance manufacturability and enable
HUGO DA SILVA (hugo.silva@dowcorning. are seeking new materials that accelerate more complex designs. Like LEDs, silicones
com) is Global Market Managerfor Lighting productivity, deliver higher yields partic- are evolving too. Recently, several leading
at Dow Corning, Lighting Solutions. Based in ularly for larger parts or reduce waste. optical and LED manufacturers have been
Belgium, da Silva leads the optical, thermal putting a new class of optical-quality mold-
and protection business for solid state lighting New materials able silicones to the test in their designs, and
devices such as LED, OLED and innovations All of these challenges effectively repre- seeing positive results.
related to lamps, modules and luminaires sent growing pains for an emerging light- While some grades of silicone are trans-
applications. ing segment that is quickly evolving past parent, moldable silicones such as those

LEDsmagazine.com OCTOBER 2012 57

 ________________________________

__________ _______

recently introduced by Dow Corning repre-
sent a more advanced material engineered
expressly for LED applications, which is
to say they compare well in performance
against todays best-in-class optical mate-
rials. Plus, like conventional silicone mate-
rials, moldable silicones exhibit low viscos-
ity before cure, enabling them to be molded
more easily into complex shapes than either
organic polymers or glass, offering new
design options for secondary lenses, light
pipes, light guides and other optical compo-
nents. This quality can also help reduce man-
ufacturing costs and cycle times in injection
molding and other processes, and potentially
reduce system costs for LED-illuminated
lamps and luminaires. Lastly, compared to
many organic materials, the chemical back-
bone of silicones makes them particularly
well suited to manage the increasingly high
temperatures of todays and tomorrows LED
lighting systems.
Hotter LED designs
High-heat applications are where mold-
able silicones shine. As a class of high-per-
formance materials, they easily withstand
temperatures of 150C and higher without
significant loss of optical or mechanical
performance. These qualities will become
more attractive as LED sources increasingly
deliver more intense white light from com-
paratively smaller package sizes, and as cus-
tomers seek smaller lamps and luminaires
with higher luminous flux, which will also
drive up temperatures at the device level.
As lumen densities increase, the package
temperatures within todays high-brightness
LEDs are already reaching as high as 150C.
This not only poses challenges for epoxy
encapsulants conventionally used to seal
LED packages, it is also raising heat expo-
sure for traditional secondary optics mate-
rials such as polycarbonate (PC) and acrylic.
In general, the optical quality of these plas-
tic materials declines over time at temper-
atures above 125C and 95C, respectively.
The same applies to epoxies at temperatures
above 150C.
Such high temperatures cause traditional
optical materials used in LED lighting sys-
tems to yellow with age, which diminishes
the total system light output. Th is can have
a profound impact on lumen maintenance
and efficiency dropping the expected 80%
LEDsmagazine.com
Polycarbonate
Cyclo-olefin
copolymer
Acrylic
Silicone resin
Materials aged at 200C for 24 hrs
FIG. 2. Moldable silicones performed well
in tests that compared their thermal and
optical stability against conventional
materials, such as PC, acrylic and epoxy.
lumen output below acceptable levels earlier
than the expected 50,000 hours of an LED
light sources useful lifetime. Further, yel-
lowing can adversely change an LEDs color
temperature over time. Such shifts in a light
sources color are unacceptable to lighting
designers and end-users alike.
In comparison to conventional materi-
als, moldable silicones retain their excel-
lent optical stability and transparency even
after prolonged exposure to temperatures
upwards of 150C, exhibiting compara-
tively little or no yellowing and greater reli-
ability across the visible spectrum. Indeed,
this emerging class of silicones enables LED
optical components to maintain their lumen
output and efficiency better over the course
of an LEDs useful lifetime.
Thermal testing
Thermal aging tests performed by Dow
Corning in an air-circulating oven at 150C
for up to 10,000 hours demonstrated that sil-
icones high optical transmission remained
steady ranging from 90-95% in the visible
spectrum under such conditions. Moldable
silicones also retained their high perfor-
mance for other optical qualities during
aging under high heat, including reflection,
low haze and stable refractive index.
Moldable silicones also stood up well in
related tests that compared their thermal
materials | SILICONE
and optical stability against conventional
materials, such as PC, acrylic and epoxy.
Thermally aged for 200 hours at 150C,
moldable silicones retained their high opti-
cal quality (Fig. 2). In contrast, incumbent
organic materials exposed to identical con-
ditions began to show significant yellowing
as temperatures exceeded 125C.
The outstanding thermal and optical sta-
bility of moldable silicones may be enough
to inspire new LED designs. These materials
can help resolve issues such as glare control
while maintaining efficiency, color temper-
ature stability and performance over time.
But in addition to this, silicones low viscos-
ity before cure further enables designers to
consider LED components with more com-
plex shapes, thinner wall confi gurations,
dual functions or very fine features.
Silicone structures
Structures like undercuts, for instance,
are difficult to easily achieve with plastics
because they cannot be easily released from
the mold. Fabricating parts that adjoin thin-
and thick-wall sections is also more chal-
lenging with plastic, which is more brittle
and therefore more prone to cracking or
breaking. Lastly, designs that use plastic
materials typically keep them away from the
heat of the LED light source, which precludes
configurations that shift plastic optics closer
to or even touching the LED.
Like conventional silicones, optical-grade
silicones are well-suited to precision mold-
ing applications. Before cure, the viscosity
of silicones decreases as heat increases. This
allows silicone resins to be injected into a
mold at lower pressures than what is typical
for other materials, while still achieving good
flow and reproduction. For example, their low
viscosity enables replication of micrometer-
sized features on a lens surface that, in turn,
offers advantages in enhancing, focusing or
directing light output.
In short, the physical properties of mold-
able silicones enable new designs that would
be otherwise very challenging to achieve
with incumbent materials, allowing for the
exploration of new shapes, styles and sizes
of LED lighting, as well as new applications.
Fabrication techniques
Silicone-based components can be fabri-
cated using a variety of techniques, including
OCTOBER 2012 59
materials | SILICONE
injection molding, casting/cavity mold-
ing and others. While naturally very
flexible, their hardness may be tuned to
either absorb vibration or deliver excel-
lent impact resistance. With their low
moisture uptake and ability to with-
stand harsh environmental effects,
conventional silicones are already fre-
quently used by the electronics industry
to protect fragile components against
damage. Moldable optical silicones
deliver many of the same advantages.
Shrinkage is another familiar chal-
lenge for plastics that is not as much of
a problem for moldable silicones, which
need not be cooled in the mold as long as
plastic in order to prevent warping. This
helps reduce cycle time particularly for
large parts which is important since the
length of time that a part must remain
in the machine can represent an impor-
tant portion of its total cost, depending
on the mold, optical part design and pro-
cess factors mentioned above. In addi-
60 OCTOBER 2012
FIG. 3. A finished LED lamp might
incorporate over ten different
Secondary optics
(diffuser) silicone-based components,
Optics including adhesives, pottants,
(remote phosphor) secondary optics and encapsulants.
LED chip
encapsulants Reflector materials tion, the comparatively low shrinkage
of moldable silicones helps minimize
Conformal coating/ or prevent warping in components that
white reflection
integrate straight sections, such as the
Thermal
interface materials back of semispherical optics.
The design and manufacturing
advantages of moldable silicones can-
Adhesives for
not be overstated because they allow
environmental issues to be solved early in the LED
seals design chain. A finished LED lamp
Conformal coating
might incorporate over ten different
silicone-based components, including
adhesives, pottants, secondary optics
Thermal pottants Thermally conductive
and encapsulants (Fig. 3). Silicones are
for heat control encapsulants for well known for addressing challenges
power components at the package level, and as LEDs pen-
etrate into general lighting those chal-
lenges will become more common.
________________
LEDsmagazine.com

Optics example
Referring back to Fig. 1, LEDiL, a leading
optics supplier to the worlds lighting man-
ufacturers, recently demonstrated this with
the development of its innovative Strada-FT-
TPHS lens module. The product of a collabora-
tion between LEDiL, Dow Corning and other
suppliers, the module features secondary
optics comprising an asymmetric lens fash-
ioned from Dow Cornings moldable silicones.
Notably, LEDiLs application of mold-
able silicone technology enabled the sec-
ondary optics to perform dual functions.
In addition to creating an asymmetric for-
ward-throw light distribution pattern, the
secondary optics also provide ingress pro-
tection (IP) for the LED package. By using
the lens material as a seal against outside
dust and moisture, LEDiL was able to reduce
the overall number of parts and address a
challenge that would normally have fallen
to its luminaire customers further down the
design chain. Namely, its customers would
have had to seal the entire luminaire.
Moldable silicones enabled further design
features for the module, such as an undercut,
and thermal and optical stability from -450 C
to 1500C to prevent yellowing over the course
of the modules lifetime. Neither these features
nor the secondary optics dual functionality
would have been easy or even possible using
plastics, underscoring the versatile design
possibilities that moldable silicones offer.
The performance demands may vary
wildly between one LED design and another
in todays evolving lighting industry. But
moldable silicones are finding applica-
tion at every level of the LED design chain
at other top optical suppliers and lighting
designers. Further, Dow Corning is con-
tinuing to seek new industry partnerships
to develop innovative new applications for
moldable silicones.
In terms of performance, moldable opti-
cal silicones combine and often exceed the
best qualities of both organic polymers and
glass. As demand for LED lighting acceler-
ates over the next decade, moldable opti-
___________
materials | SILICONE
cal silicone materials will play a major role
in the development of new high-performing
LED light sources, and help expand design
and processing options for LED lamps and
luminaires. Their good thermal stability,
moldability and mechanical properties offer
benefits at virtually every stage of the LED
value chain solving challenges to sealing,
protecting, adhering, and shaping light. With
the addition of their attractive optical qual-
ities, moldable silicones can address design
issues such as diff usion and glare control,
color temperature variation and perfor-
mance over time. Moldable silicones offer
the potential to advance the adoption of LED
lighting, drive down cost and help expand
the technology into new markets, such as
general and accent lighting for home, office
and retail spaces, traffic lights and other out-
door lighting, mobile devices and automo-
tive interior lighting. Silicone-based LED
lighting could especially benefit applica-
tions that require a cool touch and envi-
ronmental toughness.
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standards | LED WAFERS

SEMI committee progresses in

HB LED standards process
JIANZHONG JIAO discusses the progress made in the SEMI organization on LED manufacturing
standards, including a Wafer Task Force draft document, that should ultimately lead to more efficient
and less expensive components for SSL.

W
ith the ever broadening avail- After the HB LED Committee was formed, and 150-mm diameter wafers that have either
ability of LED products for gen- several task force (TF) proposals were ini- flat or notched fiducials (alignment marks).
eral lighting and other applica- tiated and discussed. So far, the committee The standard specifies the requirements of
tions, many new standards have been, or are has approved the establishment of three TFs wafer dimensions, surface characteristics,
in the process of being developed. Primarily Wafer, Equipment Automation, and Impu- physical properties, and methods of measure-
these standards are LED product based stan- rities and Defects. ments suitable for determining the character-
dards and in general they can be categorized istics in the specifications.
into three areas testing, performance, and Wafer Task Force There is some debate
safety. The standards can also be grouped into The Wafer TF has drafted a whether or not this type of
component level and system level (final prod- document for specifying sap- standard is even necessary.
uct) standards. Standards are the measure of phire wafers that are intended Some LEDs makers are ver-
the industrys maturity and are used as tools for use in manufacturing tical integrators who make
to interface between product producers and HB-LED devices. This docu- wafers specifically for their
product end users. The next step for the indus- ment is designed to serve as the own LED package products.
try is developing LED process related stan- link from wafers to LED pack- SEMI members and Wafer TF
dards that should ultimately yield lower-cost age production. Currently sap- participants believe the stan-
LEDs for solid-state lighting (SSL). phire wafers are widely used dardization of sapphire wafers
In early 2011, the Semiconductor Equip- in producing HB-LED devices, is an effective approach to
ment and Materials International (SEMI) and these LEDs are used in reducing inconsistency, and
organization formed the High-Brightness multiple applications including SSL. The in turn, beneficial to the LED industry.
(HB) LED Committee. This committee was committee believes that improving manu-
formed to create specifications, guidelines, facturing efficiency and enabling cost reduc- Specification scope
and practices for LED manufacturing at the tions are critical elements in continuing to What should be included in the specifica-
process level with the intent to improve com- advance the industry. Furthermore, SEMI tions, however, may not be as easily agreed
munication between LED makers and sup- recently conducted surveys that help to iden- upon by all TF members. There are some ele-
pliers of HB materials, carriers, and automa- tify key parameters and dimensions criti- ments of the specifications such as the epi-
tion systems. Th is approach of developing cal to enabling manufacturing automation taxial growth method that can be strongly
LED process standards, according to SEMI, across multiple manufacturing steps. dependent on specific LEDs and a compa-
should enhance the manufacturing effi- The drafted scope of the new SEMI standard nys technological advantages. Other param-
ciency, capability, and shorten the time-to- is to cover the single-crystal, high-purity, sin- eters such as a wafers flatness, scratches,
market, as well as help reduce overall manu- gle-side-polished, C-axis sapphire wafers used etc., could be dependent on the mutual pur-
facturing cost in the LED industry. in HB-LED manufacturing. It includes 100- chase agreement between a wafer maker and
an LED maker based on commercial values.
DR. JIANZHONG JIAO, Director of Regulations and Emerging Technologies at OSRAM Opto After deliberation by the Wafer TF members,
Semiconductors, Inc. is an internationally recognized lighting expert. He has been actively it is likely that the standard will include
involved in LED and SSL standard development activities. He serves as the Chairman of the agreed upon specifications as a require-
SAE Lighting Committee, past Chairman of NGLIA, past Chairman of the NEMA SSL Technical ment. Other characteristics that the TF can-
Committee, active member of IESNA Testing Procedure Committee and Roadway Lighting not reach consensus on as firm requirements
Committee, ANSI SSL Working Groups, Standard Technical Panel of UL8750, standard committees will be listed as recommendations.
in IEEE, CIE USA, SEMI, JEDEC and other organizations. He can be reached at jianzhong.jiao@ So far, two thicknesses of 150-mm diam-
osram-os.com eter and one thickness of 100-mm diame-

LEDsmagazine.com OCTOBER 2012 63

standards | LED WAFERS
ter wafers are included in the standard. For
the 150-mm wafer, the standard will specify
two fiducial configurations: flat and notched.
For the agreed upon properties such as the
dimensions and geometries, the standard
provides target values and tolerance ranges.
These specified values are based on todays
practices and are widely accepted by both
wafer and LED makers.
To promote consistent interfaces between
wafer producers and users, the standard
provides ordering information as part of
the requirements. In a purchase or contract
agreement, a list of specifications is to be used
in a table format. Furthermore, the require-
ments for each specified item are also pro-
vided in the standard. These requirements
LINKS
LED wafer and automation standards are on the fast track, ready for more industry feedback
www.ledsmagazine.com/features/8/10/9
Semiconductor industry moves toward automated LED production on 6-inch wafers
www.ledsmagazine.com/features/9/9/11
include general characteristics of the crys-
tals, dimensions, permissible variations, and
inspection characteristics.
Recommendations
The standard also provides the method of
measurements as a suggestion. It does not
preclude other methods agreed upon between
suppliers and customers. Many of the meth-
ods of measurements recommended in this
document are cited to other SEMI standards
that are used in the semiconductor industry.
For example, the wafer orientation measure-
ment references the SEMI MF26 Standard. For
some methods such as measuring flat fidu-
cials, there is no existing SEMI standard and
the Wafer TF is working to establish a specific
recommendation. If the agreement cant be
reached within the TF, these methods will
most likely be referred to as the agreement
between supplier and customer.
Similar to the Wafer TF, the members in
the Equipment Automation TF are working
to develop the agreed upon specifications.
The LED industry wants to make the process
of manufacturing LEDs more consistent or
standardized.
How much can these standards benefit the
entire SSL industry? We wont know overnight
nor will it be easy to quantify the benefits.
SSL is an industry that produces hardware
devices that directly interface with users in
their day to day lives. Some products require
user interaction, as is the case with commer-
cial building lighting which forces the user
to take action when they enter into a hotel
or office. As an industry, it is crucial that any
standardized approach that could eventually
benefit users, whether to improve energy sav-
ings, safety, quality of light, or reduce cost, be
given its due diligence.
__________________
_________________________________
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design forum | LED ARCHITECTURE
Design considerations for
enhancing LED efficiency
Understanding LED design, manufacturing, and packaging can allow lighting manufacturers and
designers to deliver optimal solid-state lighting, explains THOMAS DAVENPORT of Synopsys.
P
hosphor-converted white LEDs are
ubiquitous today, although there is
still significant room from improve-
ment in terms of optical efficiency. Packaged
LED manufacturers spend considerable time
constantly improving all elements of com-
ponent design, manufacturing, and packag-
ing to optimize efficiency. In this article, we
will cover the latest trends in chips, optics
and package architecture. These details
are increasingly important all of the way
through the solid-state lighting (SSL) supply
chain and even lighting designers and speci-
fiers need to understand the unique proper-
ties of LED sources.
LEDs have a rich history, and many peo-
ple on many continents have put quite a
bit of work into them over the last several
decades. The first LEDs we would recog-
nize as such today were red and arrived in
the 1950s, followed by yellow, orange, and
green LEDs in the 1960s and 70s. The semi-
conductor materials for these colors are the
gallium phosphide (GaP) materials: gallium
arsenide phosphide (GaAsP), aluminium gal-
lium indium phosphide (AlGaInP), and GaP.
These early LEDs were acceptable for
some applications, such as indicator lights,
but without higher power and a blue source,
they were not suitable for general, white-
lighting purposes. Fortunately, a break-
through from Shuji Nakamura (while at
Nichia) in the early 1990s solved this prob-
lem. He developed nitride-based semicon-
ductors specifically those using indium
gallium nitride (InGaN) which allowed
blue light to be produced.
After blue was available, it was found that
green could be made with InGaN materials.
THOMAS DAVENPORT (tdavenpo@synopsys.
com) is a systems engineer in the optical
solutions group at Synopsys.
LEDsmagazine.com
a)
Electrodes
Emitted blue ray
p-type GaN
n-type GaN Junction layer:
InGaN QW structure
Sapphire
FIG. 1. Typical blue LED configurations: (a) A top-emitting configuration for InGaN
blue LED grown on sapphire substrate. (b) The entire chip is flipped so the top layer
of the chip is the sapphire.
There was also a substantial effort to improve
red LEDs (e.g., for stop lights and tail lamps
on cars), and some design teams pursued
white-light solutions using RGB mixing (for
instance, using AlGaInP to make red and
InGaN to make green and blue). For many
general lighting applications, however, the
RGB approach has been abandoned in favor of
InGaN-based, blue-LED-chip-plus-phosphor
(typically yttrium aluminium garnet (YAG)
materials) solutions. The phosphor-converted
LEDs are simpler, more robust devices when
white light at a single color temperature is
desired, requiring no active color feedback
electronics, and fewer individual LED chips.
Configurations
For InGaN-based LEDs, the GaN-type epitax-
ial layers (crystalline deposition layer in this
case the GaN materials over a crystalline
substrate that it is in registry with) are typ-
ically grown on a sapphire substrate, or in
some cases silicon carbide. Sapphire is chosen
due to its wide availability, crystalline sym-
metry, ease of handling, and transparency.
Often sapphires transparency is utilized
in a fl ip-chip configuration, where the p-n
b)
Carrier with
electrical contacts
junction materials are first grown on top of
the sapphire. Then, the chip is fl ipped over
so that the top surface is the transparent
sapphire. Fig. 1a shows a top-emitting blue
InGaN LED configuration and Fig. 1b shows
the fl ip-chip approach, where the sapphire
is the outer substrate. In addition to pre-
senting a typically lower-refractive-index
substrate (i.e., sapphire) to the surround-
ing material, this approach also requires
no bond wires. A laser lift-off technique has
also been developed, and in LEDs employ-
ing this approach, the sapphire substrate is
removed after the flip occurs, resulting in a
thinner chip with a GaN layer at the top that
is more suitable for texturing than sapphire.
Texturing can improve light extraction. In
any case, phosphor is applied to the emitting
surface to produce white LEDs.
LED efficiency
LED efficiency has multiple components.
It can be divided up into at least five parts:
electrical , the electrical contacts and resis-
tance losses; IQE , the internal quantum
efficiency of the active layer; Lex, the light
extraction from the chip; phosphor , the
OCTOBER 2012 67
design forum | LED ARCHITECTURE

Increased a) b)
a) Silicon b) escape cone
chip Air Electrode
Emitted
blue ray
Point
source n-type GaN
Rays that InGaN QWs p-type
An escaped GaN
escape
cone Carrier Ag reflecting
substrate layer/electrode
p-n junction Silicone dome,
n = 1.47
FIG. 2. Escape cones for light in an LED: (a) One of the escape FIG. 3. Flip-chip LED using recycling: (a) A 2D configuration of
cones shown for a point source in a silicon medium that is the system shows that rays that dont exit the chip immediately
surrounded by air. (b) Si chip is immersed in a silicone dome much are randomized and strike the reflecting layer below giving
larger than the chip size; thereby increasing the escape cone. them multiple chances to escape. (b) A 3D view of the system
shows the textured n-type GaN surface on top.
phosphor conversion efficiency when making white LEDs; and
package, the light extraction out of the LED package. The total wall and never get out. For a rectangular solid chip, there may be up to
plug efficiency of a blue LED without phosphors, for instance, can six escape cones depending on whether or not transmissive materi-
be expressed as follows: als are used above and below the p-n junction. However, one of the
cones typically is in the direction of a substrate and rays that would
WPE = electrical * IQE * Lex * package have escaped are either absorbed or reflected.
One of the escape cones for a Si chip in air is shown in Fig. 2a. Rays
The total white-LED efficiency also includes the phosphor conver- above the cones half-angle (given by TIR) totally internally reflect and
sion, and is more complex, since only a portion of the LEDs flux is then stay in the chip. One way to improve the situation is to immerse
converted. Devices using a fl ip chip with the laser lift-off technique the chip in a surrounding index that is higher than air. Typically, the
and a proprietary, high-reflectivity silver (Ag)
layer as a mirror (pioneered by Osram) have a) b) c)
been shown to give a total wall plug efficiency Phosphor
z
z
of 53.3% for a blue LED. y x y x
z
Light extraction efficiency
x
Now lets briefly consider some of the different y
efficiency factors separately and to see how to Phosphor Phosphor
maximize them. Light in the LED is produced
at the p-n junction when an electron-hole pair
combines and a photon is emitted in the pro- FIG. 4. LED phosphor configurations: (a) A conventional phosphor slurry. (b)
cess. Thus, photons are created inside of a Conformal phosphor coating on the chip surface. (c) Remote phosphor coating
material rather than in air where we would applied inside a remote optic.
ultimately like them to go. Th is is a problem
because the refractive index of the chip material is high compared material used is silicone, with an index of roughly 1.47. Immersing the
to that of air. In fact, if we immerse the chip in any material of lower Si chip in silicone increases the escape cones half angle to 22.8. A dome
refractive index (such as air or silicone), the rays striking the chip/ larger than the chip is typically used, since it results in very little refrac-
air interface will totally internally reflect (TIR) if the incident angle tion (ray deviation) and therefore does not cause further TIR issues.
is above the TIR angle. The TIR angle is given by rearranging Snells The problem shown here can also be thought of as an tendue mis-
law of refraction where n represents the index: match between the source and the index we would like to put light
intonamely, air. tendue is a preserved quantity in an optical sys-
[
noutside
TIR = ArcSin nchip ] tem and is given by:

Thus, this angle will change depending on the chips index and
that of the surrounding medium. Some common chip materials
include: crystalline silicon (Si) with an index in the 3.0-4.0 range,
GaN with an index of 2.3, and sapphire with an index of 1.77.
If the chip material is Si and it is placed in air, then TIR = 15.3
using nchip = 3.8. TIR defines the half angle of a cone, and rays out-
side of this escape cone in the Si can become trapped in the chip
tendue =(Refractive)2 Area Projected Solid Angle = Constant
This equation implies that in an optical system, the source size, its
projected angular extent, and its surrounding refractive index define
a constant tendue value. If we try to squeeze this tendue into an
area of the same size, but with a lower refractive index, and the pro-
jected solid angle of the source is already full (as in this case), there

68 OCTOBER 2012 LEDsmagazine.com


will be angular clipping of the flux. Th is is
exactly what we see going on here.
tendue also has other consequences. For
instance, if we want to collimate light from
a Lambertian source (like a flat cast LED),
it shows mathematically that the output
aperture will have to increase in area as the
angular extent of the light decreases. If you
dont increase your aperture size, then light
will be lost due to spatial clipping. If you like
small aperture sizes, it pays to avoid diluting
the source tendue if possible.
As shown in Fig. 2b, we immersed the chip
in a lower index material and allowed the out-
put surface to grow in order to ease the ten-
due mismatch. Another approach to help this
problem, now standard in the backlight dis-
play industry, is to use scattering (in this case
textured) surfaces in combination with light-
ray recycling. This approach is utilized in
many flip-chip GaN systems, including those
with laser lift-off removal of the sapphire layer.
In Fig. 3a, we show a 2D image of how this
type of recycling system works. Light is gen-
design forum | LED ARCHITECTURE
Relative flux out of dome
1.00
0.98
0.96
0.94
0.92
z 0.90
y 0.88
x
0.86
0.84
0.7 0.9 1.1 1.3
Dome radius (mm)
FIG. 5. The radius for an LED domed impacts flux output. A 1x1-mm chip is immersed
in a silicone dome (left). The domes radius is varied and the fractional flux out of the
dome on the first pass is shown in the plot. A radius of 1mm lets >99.9% of the light
outneglecting Fresnel effects.
erated at the InGaN quantum well junction view of the chip structure with an example
layer. If it goes upward, it encounters a tex- randomized texture. One consequence of
tured interface at the GaN/silicone bound- this approach is that an electrode is required
ary and may refract and escape. If not, it is on the top surface.
reflected downwards at a randomized angle
and then encounters the highly reflective Ag Phosphor efficiency
surface at the bottom of the p-layer and goes Another critical aspect of phosphor-
through the chip again. Fig. 3b shows a 3D based white LEDs is the phosphor itself. In
design forum | LED ARCHITECTURE

modeling phosphor mate- Flat LED spatial Relative en-squared flux Best focus location,
y (mm) distribution y (mm) domed LED
rials, there are many items
Flat-cast LED
which must be measured or 1.2 1.0 1.2
inferred. For instance, one 0.6 0.8 0.6
98% point for
needs to characterize the dome source
0.0 0.6 0.0
absorption spectrum of the Virtual
phosphor particle, the emis- -0.6 0.4 image formed
-0.6
by dome
sion spectra, the quantum 0.2
-1.2 -1.2
yield (or excitation spec- 0.0
-1.2 -0.6 0.0 0.6 1.2 0.0 0.5 1.0 1.5 2.0 -1.2 -0.6 0.0 0.6 1.2
trum), the mean free path x (mm) Squares half length (mm) x (mm)
of the phosphor, the parti-
cle size distribution, and the FIG. 6. Flat emitting LED illuminance and domed LED illuminance at best focus. Spatial distribution
intensity distribution from at the LED surface is shown on the left for the un-domed LED. On the right is the virtual best-focus
interactions that do not plane illuminance for the domed LED. The effective source area is roughly quadrupled by the dome.
result in a conversion.
Once a phosphor model is created, one can be increased dramatically, thus diluting the above the emitting surface of the chip (that is,
adjust the phosphor density in the matrix, source tendue. away from the chip and towards the domes
among other parameters, to tailor the spec- vertex). In Fig. 6, we show the illuminance dis-
trum to a desired color temperature. Also Package extraction efficiency tribution at the surface of the LED without a
important for white LED sources is the There are two primary types of LED pack- dome on the left, and the illuminance distri-
color rendering index (CRI), or how well the age architectures that have emerged over bution at the best focus plane for the domed
spectrum can render a set of test colors. For the years: dome and flat cast. Additionally, LED on the right.
LEDs, other metrics such as the newer color there are some LEDs that are sold with more In the center of the two raster images, the
quality scale (CQS), similar to the CRI but exotic optics incorporated on top of the chip en-squared flux is plotted for both config-
using more saturated reference colors, and for instance, LEDs designed to make a urations. The chip without a dome shows
gamut area index (GAI), may also be impor- batwing distribution. For the most part, the a sharp cut-off at a 0.5-mm half-length as
tant in a given phosphor design. LED manufacturers supply dome or flat cast expected. However, the effective size of the
Another issue related to phosphor effi- LED sources, and optical designers choose source is increased dramatically for the
ciency is the geometric confi guration one from an array of off-the-shelf output optics domed LED. The 98% en-squared energy
should use. Traditional LEDs included a or design their own optic implementations. occurs at 1.1-mm half-length. Th is means
phosphor slurry sitting in a cup as shown in Typically, when the most important spec- that the effective source area has roughly
Fig. 4a. Because of the different path lengths ification in your application is total lumens, quadrupled. If you want to capture all the
from the blue chip through the phosphor, dome out-coupling optics provide a better light in your optical system, the size of your
this configuration tends to give an intensity solution. However, if you want to preserve optics must increase to accommodate this.
distribution that is bluer in the center and your source tendue as well as possible, then In addition to the tendue problem, it is
more yellow at higher angles. flat cast is usually a better choice. As pre- typically much easier to work with a planar
Fig. 4b shows a conformal-coating phos- viously discussed in this article, preserving source than a hemispherical one. A planar
phor that follows the chip shape more care- the source tendue is critical in many situa- source allows, for instance, the use of clas-
fully and gives a much more uniform color tions, such as when the aperture size of your sic angle-to-area converters such as a com-
over all angles. Th is type of LED has now optic is constrained. pound parabolic concentrator (CPC) and can
become standard and has the added ben- reduce design complexity. From a designers
efit of preserving the sources tendue bet- Coupling to an optical system point of view, the best LED source might be
ter (it does not increase the effective source To explore the tendue issue more closely, Lambertian, perfectly spatially uniform
size very much compared to other phosphor consider the following example: a square LED (maybe even circular instead of square!),
approaches). chip that is 11 mm emitting green light with planar, and have efficiency equaling dome
Fig. 4c shows a third approach that some and without a dome made of silicone with an approaches. Thus, there is always room for
design teams are now working onremote index of 1.47. In Fig. 5, we show the domed improvement, and both dome and flat cast
phosphors. There are many remote phosphor system geometry on the left and the relative packages will likely be around for a while.
configurations possible, but in the example source flux exiting the dome on the first pass In this article, we have delved briefly into
shown, there is a hollowed-out transparent to the right. A relatively modest dome radius the history of LEDs and the main design
dome placed over a blue LED and a yellow of 1mm allows >99.9% of the chip flux to exit. configurations used. Additionally, we have
phosphor coating is applied to the inside Next, lets set the dome radius to 1mm and looked into the sources of LED efficiency loss
surface of the dome. This approach tends to then defocus all of the exiting rays back to a and explored design techniques for increas-
have even better color mixing than confor- plane of best virtual focus. In this example, ing the efficiency of the light extraction from
mal coatings; however, the source size may the best focus occurs at a distance of 0.17 mm the chip, phosphor, and package.

70 OCTOBER 2012 LEDsmagazine.com

 2013

FEBRUARY 12-14, 2013

Santa Clara Convention Center Santa Clara, CA USA

REGISTER BY DECEMBER 14, 2012

FOR EARLY BIRD SAVINGS. WWW.STRATEGIESINLIGHT.COM
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This event is fantastic and exceeded our expectations. The quality of the
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PHOTONICS LEDS LIGHTING

last word
SSL will find use beyond general
lighting as LEDs control the
electromagnetic spectrum
Adaptive lighting controls will improve our health and wellbeing, and SSL will
add communications capabilities as new LED-based products control the
electromagnetic spectrum in real time, explains NEXT LIGHTING CTO STEVE PAOLINI.
O
ne way to take the pulse of solid-
state lighting (SSL) is by regu-
larly purchasing LED replacement
lamps. With installed sockets in the billions,
its hard for the newcomers to resist a run at
this market even if its not the best way to
utilize LED technology. The quality and per-
formance of the better SSL products now on
the market often exceed the vacuum incum-
bents, so it would seem only price remains as
the final hurdle to clear on the way to the fin-
ish line. But is the finish line mass replace-
ment of vacuum lighting with SSL? If history
is a guide, there is less a finish line and more
of a journey to be taken.
Transistors did not stop developing once
they successfully replaced vacuum tubes in
radios, amplifiers, and switching gear and
neither will LEDs finish with lamp replace-
ment. Imagining these next steps is no guar-
antee its what will be, but its a necessary
step. With the L Prize lamp and other qual-
ity replacements on the market we can now
give some serious thought to and seriously
work on what lighting could really be with
this new technology.
One of the fundamental values of LEDs is
they allow us to control an important part of
the electromagnetic spectrum. Its not only
important because our eyes need it to see,
but most everything that lives on the planet
is profoundly affected by it.
One type of electric illumination Id like
to have is the light that comes through the
window on a nice day. The gradual change in
intensity and spectrum that occurs through-
72 OCTOBER 2012
out the day would be great to experience at
will. Natural light has spectral, temporal,
and spatial components that not only illu-
minate, but subliminally stimulate and sati-
ate our well being.
The night brings light from the moon, can-
dles, and the aurora borealis
that could be enjoyable to call
up on demand. Once the capa-
bility to manipulate the spec-
trum in real-time is included
in SSL, the sky is the limit as
to the type of illumination we
can have, perhaps similar to
the vast music and video cat-
alogs that exist today.
Beyond spectrum and time,
there is the distribution and
direction of the illumination. SSL could be
made to replicate the collimated rays of the
whitish sun moving across the southern sky,
while the diff use bluish light of the northern
sky changes in hue and intensity through-
out the day.
These attributes are not just enjoyable
they have circadian health, student learn-
ing, and employee productivity implications.
While SSL must become less expensive to be
widely adopted, even small improvements in
health and productivity have significant pos-
itive economic payback.
In addition, the electromagnetic spec-
trum can be used for telecommunications
and as our consumption of bandwidth con-
tinues to increase there is little doubt this
portion of the spectrum will see double duty.
Unlike radio waves, light waves dont travel
through walls, but this can be a good thing
depending on the application. Communica-
tions are more secure and bandwidth can
be completely reused in the next room. As
more colors of LEDs are used to manipulate
the spectrum for lighting they
also increase the number of
communication channels in
a given fi xture.
One startup in the Boston
area has developed a local
positioning system that piggy-
backs on an SSL installation.
Used in conjunction with a
cell phone camera and app,
it can place your exact loca-
tion inside a building and give
directions to any other place in the building.
For example, a man looking for dress shirts
in a department store could point his phone
camera toward the lights and enter a query
that directs him to shirts. Even slightly
higher turnover in the store, or less time for
the customer to find something, translates
into economic value.
In the short term, the focus is on replace-
ment lamps. Examining them carefully can
provide valuable insight into performance
improvements and cost reductions. How-
ever, there is more to SSL than lower price,
less energy, and longer life. Just around the
bend are wonderful new lighting products
and services just waiting for the market
to ask for or perhaps the next Steve Jobs to
show us what we could really have.
LEDsmagazine.com
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