The Fortronic LED& Lighting Design Forum

Transcription

1 The Fortronic LED& Lighting Design Forum Yoong Jin Hu Field Applications Engineer 27 th March 2012

2 Presentation for The Fortronic LED& Lighting Design Forum Things you hear about LEDs? Basic Advantages of LED Light: Are very energy efficient Are directional - No wasted light, any pattern possible Have very long lifetime Are inherently rugged - No filament to break Start instantly - controllable : New lighting features, power savings Are environmentally sound - no Hg, Pb, heavy metals Love cold temperatures - No cold starting issues But.. The performance will depends on the design of the Light fixture Copyright 2009, Cree, Inc. pg. 2

3 The Fortronic LED& Lighting Design Forum Topics : Lighting Class LED s for High Quality LED Lighting Introduction an overview of Cree Section 1 : Lighting Class LEDs Section 2 : High Quality LED Lighting How to achieve Section 3 : Design and Handling considerations Copyright 2009, Cree, Inc. pg. 3

4 Cree Overview March 2012

5 Cree s mission is to lead the LED lighting revolution to obsolete inefficient lighting Cree will do whatever it takes to accelerate the adoption of LED light

6 Cree A Global Company European HQ Munich Santa Barbara Material Research Durham, NC, USA 469,000 sf Huizhou, China 1,034,600 sf US : Chip manufacturing China : Cree factories for high volume production - Manufacturing Regional Application and technology Centres Global and regional Distributors for local stock & service Copyright 2011, Cree, Inc. pg. 6

7 Value of the Cree Brand Nearly 9 out of 10 lighting buyers would be more likely to purchase products labeled Cree LED inside Perceived as higher quality Cree recognized by IMS Research as the market leader in LEDs for lighting (Dec 2010) Copyright 2011, Cree, Inc. pg. 7

8 Financial Strength & Sustainability Revenue > $1 B Cash >$0.6 B Copyright 2011, Cree, Inc. pg. 8

9 Investment in R&D Driving Innovation $100+M $59M $71M $81M Advancements in lumens & lumens per Watt Larger wafers Reliability enhancements Optimized packages for lighting Copyright 2011, Cree, Inc. pg. 9

10 Proof of Technology Leadership Issued Patents Pending Applications U.S Non-U.S. 1,005 1,543 Total 1,551 2,142 Note: All totals include exclusively licensed patents IP portfolio & scale large enough to provide indemnity that matters Copyright 2011, Cree, Inc. pg. 10

11 Investment - high volume production & cost down High volume production XLamp Capacity $475M invested into capacity expansion over 3 years Cost reductions Larger Wafers - Creates Cost Reductions Improvements in Flux / Efficacy need less LEDs Low cost manufacturing ; high volumes lower unit cost Year on Year savings passed on to customers Copyright 2011, Cree, Inc. pg. 11

12 The Fortronic LED& Lighting Design Forum Topics : Lighting Class LED s for High Quality LED Lighting Section 1 : Lighting Class LEDs Section 2 : High Quality LED Lighting How to achieve Section 3 : Design and Handling considerations Copyright 2009, Cree, Inc. pg. 12

13 Lighting Class LED s - What are they? X Copyright 2011, Cree, Inc. pg. 13

14 Lighting Class LED s - What are they? Copyright 2010, Cree, Inc. pg. 14

15 Lighting Is NotLEDs Lighting-Class One Application are Not One Product FIXTURES LAMPS XT-E HVW XP-G XP-E MC-E MT-G XP-G MT-G XP-C XT-E WHT XP-E XM-L XP-E MX-3 ML-E MX-6 ML-E XP-G XB-D Copyright 2012, Cree, Inc. pg. 15 LMR4

16 XLamp LEDs and Modules Portfolio: Lighting Discretes Discretes Arrays Arrays (Directional) (Non-Directional) (Directional) (Non-Directional) XR-E XR-C XM-L HVW MC-E LMH2 XM-L EZW LMR2 XT-E HVW XP-G XP-E XP-C XP-E HEW XB-D ML-E ML-B XT-E WHT MX-6 MX-3 XM-L Optical control put more light where it is needed Design flexibility Modules Smooth look to emulate fluorescent in linear & panel lighting Uniform light & color over angle Copyright 2012, Cree, Inc. MT-G CXA2011 MP-L LMR4 LMH6 High lumen density for optical control Excellent LED-to-LED color consistency Easy assembly One component eliminates multiple shadows pg. 16 Highest level of integration Speed time to market Excellent Color Consistency

17 What Can16.5 Go Wrong: Poor quality LEDs Lowes Time zero 1000 hours LED Puck 84.1% Drop 16.5 Linear 97.8% Drop 22 Linear 96.9% Drop

18 Lighting Class LED Efficacy Developments Theoretical maximum for LED 231 LPW Cool White (lumens/watt) LPW 200 R&D Capability LPW 161 LPW LPW 3 yrs XM-L XP-G XP-E HID XR-E Fluorescent High Volume Production XR-E CFL LED Incandescent Copyright 2011, Cree, Inc. pg. 18

19 Cree Silicon Carbide Enables Next GEN Lighting Class LED Best Performance Compared to sapphire: Fewer dislocations More photons Better index matching of GaN to substrate More light extraction Inherent 5-10% efficacy advantage Best Reliability Cree s newest SiC-based LED (shown in Royal Blue for better detail of the chip) Fewer epi defects Fewer LED failures & less rework Security of Supply Only manufacturer of wafers AND chips Ability to scale production quickly SiC brings improvements optimized for lumens/$ Copyright 2012, Cree, Inc. pg. 19

20 Silicon Carbide Creates More Efficient LEDs Simple* GaN 2D ** Cartoon ** GaN SiC Al2O3 GaN on SiC 1: (3.3% mismatch) Lattice mismatches create areas where the LED is less efficient. GaN on Sapphire 1: (14.8% mismatch) SiC = 4.5x better lattice match to GaN * Drawn to scale. ** SiC, GaN, and Al2O3 are actually 3D Hexagonal crystalline structures Copyright 2012, Cree, Inc. pg. 20

21 Lighting Class LED s - Need for Quality LED Chip Determines raw brightness and efficacy Phosphor System Package Determines color point and color point stability Phosphor LED Chip Package Protects the chip and phosphor Helps with light and heat extraction Primary in determining LED lifetime Copyright 2010, Cree, Inc. pg. 21

22 Lighting Class LED s Colour stability Copyright 2011, Cree, Inc. pg. 22

23 Color Shift in Operation (XP-E, Correlation Document) Here the shifts are shown in X-Y space over the range of temperature and current These results are shown in detail in CLD AP81 rev 0, describing the correlation of measurements Copyright 2009, Cree, Inc. pg. 23

24 Lighting Class LED s Lumen Maintenance - Life Time L70 Copyright 2011, Cree, Inc. pg. 24

25 LED Lumen Maintenance Critical Parameters 1. TAIR Ambient Air Temperature 2. TJ Junction Temperature 3. TSP / TC / TS Solder-Point Temperature / Case Temperature 4. IF Forward Current / Drive Current Copyright 2011, Cree, Inc. pg. 25

26 40,000 Hour / 4.5 Year XLamp Long-Term Data Lowambient temp (25ºC) testing is LEDs a good surrogate for at all. At lower air temperature, hardly depreciate the LED chip depreciation TJ = 65ºC Copyright 2011, Cree, Inc. pg. 26

27 Lighting Class LED s Industry Standards Copyright 2011, Cree, Inc. pg. 27

28 SSL Standards (U.S.) 4 years ago: Major and reasonable objection to LED Today: TM-21 - Projecting Long Term Lumen Maintenance of LED Light Sources ANSI C chromaticity IES LM SSL photometry IES LM Lumen Maintenance UL 8750 Safety RP-16 SSL Definitions UL 8750 Most of the major pieces are in place, many more on the way TM-21 LM-80 LM-79 Being practiced and referenced widely by industry and government programs Copyright 2011, Cree, Inc. Many Others ANSI C RP-16 SSL Definitions pg. 28

29 Lighting Class LED s Lighting-Class Performance: Copyright 2011, Cree, Inc. High efficacy ( >80lm/w ) Colour stability Lumen Maintenance Conform to industry standards pg. 29

30 The Fortronic LED& Lighting Design Forum Lighting Class LED s for High Quality LED Lighting Topics : Section 1 : Lighting Class LEDs Section 2 : High Quality LED Lighting How to achieve Section 3 : Design and Handling considerations Copyright 2009, Cree, Inc. pg. 30

31 LED Lifetime Is Irrelevant System Lifetime is What Creates Value Heat Sink: Linchpin of the entire system. If this is poorly designed, all the other components can be compromised Driver: Currently the weakest point of the system, but the big companies are working on this Optical Components : Can (rarely) yellow over time and lose light; system design choice LED Lamps: Practically never fail; depreciate very slowly in a well-designed system Copyright 2011, Cree, Inc. pg. 31

32 SSL Luminaire: Multi-Disciplinary Effort Electrical Thermal Optical Integrated systems approach required LED light is different than existing light technologies Not intuitive at first Delivered lumens Delivered LPW These graphs are on all LED data sheets; familiarization with them is essential to getting good results

33 Fixture Efficacy WARM WHITE Incand 17 lm/w x Coefficient of Utilization 58% = Fixture Efficacy 10 lm/w = Fixture Efficacy 35 lm/w CFL 60 lm/w x Coefficient of Utilization 58% CA Title 24 XLamp 80 lm/w x x x Coefficient of Utilization Driver Efficiency Thermal Equilibrium 90% 91% 88%* * Including loss for thermal Tj = 65 C Copyright 2009, Cree, Inc. pg. 33 = Fixture Efficacy 56 lm/w

34 Typical Optical Losses Secondary Optics Diffuser/Glass Reflector Diffuser Lens Glass 80%-90% Efficient 60%-90% Efficient

35 Typical Driver Losses 90 Efficiency (%) Output Load (%) Generally, 80% - 85% is a good estimate but some will claim MUCH higher

36 Iterative Process: More Power = More Light 180% 160% Relative Intensity (%) 140% 120% 100% 80% 60% 40% 20% 0% Drive Current (ma)

37 But More Power = Lower Efficacy (Droop) 180% % % % 80% 30 60% 20 40% 10 20% 0% Drive Current (ma) Efficacy (lm/w) ' Relative Intensity (%) %

38 Many Opportunities For Optimization IF(mA) LPW # of LEDs Cost $ $+ $$ There is often an opportunity to trade-off drive current (IF) and thermal design for both system LPW (efficacy) and overall system cost

39 High Quality LED Lighting To achieve a high quality LED lighting design Optical design Electronic design Good Thermal design Bad Excellent BAD Bad Lighting-class LEDs Good Quality of LED Keys to success Luminaire Design BAD BAD Integrated System!! Results

40 The Fortronic LED& Lighting Design Forum Lighting Class LED s for High Quality LED Lighting Topics : Section 1 : Lighting Class LEDs Section 2 : High Quality LED Lighting How to achieve Section 3 : Design and Handling considerations Copyright 2009, Cree, Inc. pg. 40

41 Design and Handling considerations Some examples of aspects that must be considered Chemical compatibility Thermal Design Electrical over stress Copyright 2011, Cree, Inc. pg. 41

42 Failure causes and modes due to bad handling Several times LEDs failed on the field before the expected life time Failures modes were graded by order of occurrence due to. Copyright 2011, Cree, Inc. pg. 42

43 Chemical compatibility Copyright 2011, Cree, Inc. pg. 43

44 Symptoms of material incompatibility Copyright 2011, Cree, Inc. pg. 44

45 Material Compatibility Application note on cree.com Shows example compatible and incompatible material as well as test method to determine compatibility Copyright 2011, Cree, Inc. pg. 45

46 EOS Electrical Over Stress Copyright 2011, Cree, Inc. pg. 46

47 Prevention of Electrical Overstress Drivers should be developed or selected to minimize this effect Passive, or better active, in-rush current protection can also be used to reduce or eliminate this effect Copyright 2011, Cree, Inc. pg. 47

48 Thermal Good Design Bad Design Copyright 2011, Cree, Inc. pg. 48

49 Where Is the LED Junction? Copyright 2011, Cree, Inc. pg. 49

50 Light output vs. Tj Copyright 2011, Cree, Inc. pg. 50

51 Lifetime vs. Tj Copyright 2011, Cree, Inc. pg. 51

52 Thermal issue origins Copyright 2011, Cree, Inc. pg. 52

53 Thermal some definitive design information Copyright 2011, Cree, Inc. pg. 53

54 Examples of poor design Copyright 2011, Cree, Inc. pg. 54

55 Driver & Thermal Problems Driver/circuit board failure Color shift due to poor thermal design Copyright 2011, Cree, Inc. pg. 55

56 16.5 Problem Lowes Not a Binning (Poor LED Selection) Time zero 1000 hours LED Puck 84.1% Drop 16.5 Linear 97.8% Drop 22 Linear 96.9% Drop Copyright 2011, Cree, Inc. pg. 56

57 Summary: Quality Solid State Fixture Design Bad Good Thermal design Optical design Electronic design Handling Good Excellent BAD Bad and good Quality of LED Keys to success for High Quality SSL Fixtures : -Lighting-class LEDs Quality Luminaire Design BAD BAD Results pg. 57

58 THANK YOU