First in class With the advent of Chip arrays in SMD. packages, Osram’s Ralph Bertram looks at the benefits and drawbacks, in comparison with Chip-on-Board LEDs new type cf LED packages_s conquering the market: this het class of LEDs - Chp Arays in SMD Packages (CAS) ‘can generate a high bightness level of between 909 and 1800 lumens (i). They combine te high eficacy and ht output ‘of CoB (Chip-on-foare) LEDs with costeffectve and reliable assembly, using Prx&Place electronics. The prited cil board (FCB) sno longer part of the CoB, but partof the luminaire again, ‘80 thee is greater freedom of design for manufacturers. This ‘opens up adtional possibilities for including features such as thermal fuses, comectors, or even driver cemponerts drecty on the LED board. ‘All CAS current avalabe onthe market feature @ luminous fx ‘of move than 200 Im — some can evan carn excess of 1200, Im. Because o these high fux bvels, reo wth equivalent watages of 25 to 75 watts ae feasbie wth only one LED ‘package, with sufisir’ affeacy to wach EU Energy Class As ‘As inthe case ol CoB LEDs, the ightis generated by an array ‘of volume emiting (Sapphire) LED chips; however, tre CAS chips ‘10 mounted en ahighy relecivelsadame materia, o even ‘ona ceramic substrate. Allof these chips emit blue ightand are embedded ina phosphorfledsiicone material that generates ‘ite fght Therefore, simpy by exchanging the reflective PCB. ‘material wth alead frame, marufactures can ensure easy SMD assembly, without compromising th eficacy orother postive propetios of CoB LEDs, ‘See table blow: Camparson of ferent LEDs with regu amen packages, efcacy, system costs, ard relay |osam opt semieonactrs Many benefits, several challenges ‘The first generation of CAS LEDs wes designed for use in retrofits, cespecally fr drectond! MF and PAR lamps. Therefore, the men Dackages ofthese ist procucts were optimally adjusted io replace halogen lamps with 200 SOW. ‘Accordingly, they were ued a singlet sources, whhoue providing mulble spots or multiple shadows. Consequerty, hey Saisie the wishes of users who wantod to achieve he same look ‘and feel wih the new LEDS as with te halogen lamps they had been using belore. Uni then ths hac only been possible with Co LEDs, but hey need hand soldering or partshave tobe manually Insert no laos ‘This package type could alsobbe used for higher watages, requiring only one LED o be incorparated in omn-rectonal retrofits. Thanks to thei SMD peckages, automated essembiy is Pessible and the use of comectar, or oven svercempanarts, on the LED board can pave the way forful automation cf retioft and luminaire production, without cempromising appearance. Te Duis 10, fom dan Ops Seriondictrs an angle ofa CASLED ca ‘ASleadrane-ased | CAS ware pckage | 20=Dievcrame | Cwame HPLED pochage ened pockoe Tnvpieiags | KO-TOGaDI | 00 12001m =a 15001 =H 100120 Biieey 7 + 7 z = — cae aT [shen penta. | Rinne asbecnee [rari ‘item eats | Relate eh LED | Eargs rough LED Saunas hreoahystom | Conmeaty aroauet | Righer =D feeecgama™ | leet Sideteenycrcee | atrlonetqres = |cote ea Baie Base Good Baie Baek .tmgaenece.uk JANUARY 2016 + 27OPINION, Today, more end more retofts are designed wit ‘8D connectors onthe LED boat that aie the illo matrals, but est in consderable savings and addtional reiabity on the assembly side. This isthe ain reason why ts fight tkely that SMO components wil ultimately reval ove sem-autonated assemtly C08 LEDs inalhighvolime applicators Frotessenal dowmights used hi ofice bulangs anc shops se chen based on CoB LEDs, because a single light source in the centre of he luminaire offers a cenain degree ot hating contol, andiooks ie a halogen oF HD bl The equred brightness levels f 20000 3000 canbe achived witha cluster of CAS LEDs, and ater ttption ofthe PCB layout, fhe CoB provousy used can simply be replaced without any cher changes to ‘tre design, bit gunslight ouput and eficacy. Roal advantages can be achavod when the PCD ia used for mare than js provdin thera iverace. =anrnh Forexanpl,terl fuses, or exen pars of he civer ‘waa enw orth contol letencs, can beinclded onthe LED board Mounting hles can be paced where the manufacturer needsthem, and afordabe pokein comecors are also avaiable, eradicating the need for See figure: Fist solder jot fees detectable by suction ‘marual soldering orf holders. Inreaseinforardvotage. The number of temperate cycles is ‘Athough CASLECs have few drawbacks that need to be ependenton He alference in temperature taken into consieraton the edreniages deal outweigh te isatvartages, para the sal LES and the consierabie \ ‘ costachantage compared to Coes, CAS LEDs used in lighting solutior “The east assomblyo| CAS LEDS wil uimetely preva over Bath emnicirctional and dractond rots can benef rom ‘semiautomated assembly of CoB LEDs inal highwolume the use of CAS LEDs. For example, n Alamps and candelabra: appicatons. Un then, manufactures have toknow the trede- ‘ype lamps, GAS LEDs can replace a numberof smale, offs in thermal petormance, feime, end colou consisenoy, and ‘ma power LEDs ata comparabe pice. This enables tho useot ‘an easly chgose the type of LED thats parfct other ighting ‘wituafiament opics na larger range of power ciasses than at ppicaton.t preset In MR s6:ypo retrofits, CAS LEDs fer a costeffectve soluion or singe scurce halogen lookalke amps, removing the infamous mut-shadow effet However, the design ofthe optics here is ‘challenging: according othe basic rules of opie, tho 220 ta lne en alargor source has to be proportionally greeter ‘than fer a smaller source. AS ony one lone ianeoded the diameter of he optics ‘can be comparable. On the other hend, the ler is higher, requting an atonal ‘amourt of precious space inside the MA s6 shape ‘Ste Figure 4: One CAS LED can replace tree or four smaller LEDS in an MIG lamp 43030 1x 50502 Tere} ‘There ae aso afew things tht have o be considered when designing with CAS LEDs. Owing to their higherlumnous fu, the thermal loed that impacte on a CAS package i inthe range ‘ol sovral watts. Most CAS LEDs ar leadrame-based,so the LED chips replaced directly on the copperbased leactame. ‘Adding the thermal resstance ol an average pedormancs PCB, the thermal resistance vale is around 13 KW fora 1OW devi, making sighly higher then that ofa CoB. ‘Onthe beneft de, theres need tr akdtiona! electric! ‘solaton against the heat snk -the PCB should easily withstand ‘several thousand wots as requred during certfcation testing ‘according to IEC 61947 oF UL 1910. Forthe 10M device mentioned above ise inthe ypcal junction temperature against a heat sink would be 23K, compared to 21K for a CoB. See gure 1: Thermal simulation for a Duis S10.CAS device on hot plate Optics and colour Uke CoB LEDs, CAS packages o the fist generation featured acrciarightemiting suriace (LES), so thre nae ite concom in tome of optics design. Howerer, since the packages ae square by nature, itwas discovered fat eticecy could be signficaly inorecaodif the light omiting eurtaco wes also ‘squae, This is usually not very significant, but toes have an impact on optics desi. Comared to CoB, LEDain the some power class, the diameter the ‘CASES stl smal (-10mm) ‘Another important aspect to consideriscolou consistency: snice the CAS willprobabl furetion ‘as the ony light scure in an end product. colour binning has tobe carried out carefully to aveid ‘vations rom lap tolamp when mounted in te ‘sameinstalaton. Materials and robu ‘Since most ofthe designs evallable on the market Cortain the sof mets siver nthe eadtame mara ‘andplatics as her housing material, robustness |S queston. ‘The leadtame is both the supporting mechanical structure and the thermal and electrical contact to the oad, As in CoBs, the leacame of CAS LEDs als serves as amino. to help emt the ight fom the package. It therefore needs to have excelent rflecive Dropertes, end shoud typicaly be silver coated. $0 the presence of corosive(especally sure) gases leads to accelerated ageng that reduces he brightness ofthe chips. Mostof the cenceme with CAS LEDs relatato the ageng of plastic materials at hightemperetures andintense igh levels, so exposure of the package ‘material to Bue ight must be limted, Since, i lrg packages, the asic surface exposed to light can be ‘mirimised in relation othe mor or badrame sutace, package ageing canbe reduoodto aminmun. tho latest generation of epon-besed mateialis used, the packages can echt LV‘8ietines that are sufficient for mest applications ‘See igure 2: LV-80 data iftime) ofthe frst goneaton of the ‘Osram Duns 88. Tests wit the second gororaton withimproved sion, ae curenty ongoing ness nen t comes to choosing terigh design, efeacy, costs, ‘andlfeime interdedtor the product mustbe consdered, For ‘example, in consumer reroft appicatons,igting soltions ‘suchas lamps or uminares needto wisn several oft cycles par cy. As the ciference in thermal expansion between the copper leadttame and the aluminum core ofthe boards ‘minimal, tis agvsabe to useleactrame-based CAS LEDS or appleatonsin ubich{requer, and/orhigh temperature cycles, ‘are expected, Th strain on the solder jos is greater as the deme gets gecoud Timing, content and context Ensure backgoourd light is ‘alenced fr vival como: rot Joo mc contrast between task Infomation, such as notes and your screen Gets bight ht inom aut waa syigh' ~ otherwise use aici ight EEnoure background ight 's balanced fr visual ccomiort and of suitable brightness fr the ype of leisure actvty "Gradual reduce background ight ‘eng eslocive swtching, dimming, oF ~_Binds/sheersicutains on windows Hp tat datness- ideal sing utans rahe han A naga ‘Alou your eyes ‘cust om ful darkness before opering cutains ‘loving dayight to exterthe space, and before checking it ovis, ouch asa tablet or prone Ensue that background lights of suleble brightness forthe task rol, crease ight localy Vary your enwrorment Get seme bright hot — idealy 270.minute wan daylight but fmol, use ‘aical ight Consider single Sony crease ne changes such as mount igh ing beige ight te selene swtchig, tatroomer chen inal 8 aa al windows Get some brat ioht— ttyou ee te, idealy fom 220 ti ce your eyes and tie wn dig aay longer to thats nat possible, Use ‘ais toe ‘wtih ‘moning Vary you it envecrment during Ihe workng mong -beighter oF drmmes= walk get coffe, Jocus on cifreni tasks for afew mines, enjoy the vew Taisen eee See ore rmosire rit Secon ears ae ice am Seve tere Se tee! wierd Meo eo iaes Meera tr Senrccomga ore Senn a, eee rotons ferlveugere a Cpr Priced Seceonet eas cee ove wean tng Saree Sere Teekintee otter areca ie Ciplacrale say Biro ts ane bow ot ermbing rember erpererce_ (UN this att hand