led magazine - march 2014

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IP and patents Phosphor technology Q&A P.21 US DOE Lessons learned boost LEDs P.33 Simulation Thermal-electrical SSL analysis P.65 LEDsmagazine.com MARCH 2014 UNESCO Heritage Site SSL highlights architecture, limits light spill P.26 TECHNOLOGY AND APPLICATIONS OF LIGHT EMITTING DIODES

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LED Magazine - March 2014

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Page 1: LED Magazine - March 2014

+IP and patentsPhosphor technology

Q&A P.21

US DOELessons learned

boost LEDs P.33

SimulationThermal-electrical

SSL analysis P.65

LEDsmagazine.com

MARCH 2014

UNESCO Heritage SiteSSL highlights architecture, limits light spill P.26

TECHNOLOGY AND APPLICATIONS OF LIGHT EMITTING DIODES

1403leds_C1 1 3/3/14 4:27 PM

Page 4: LED Magazine - March 2014

LEDMAGFeb2014

© 2014 Cirrus Logic, Inc. All rights reserved. Cirrus Logic, Cirrus, the Cirrus Logic logo designs,EXL Core,

and the EXL Core logo design,TruDim and the TruDim logo design are trademarks of Cirrus Logic, Inc.

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1403leds_2 2 3/3/14 4:26 PM

Page 5: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 3

2014features

21 INTERVIEW

Intematix expands phosphor development and IP

to meet demanding SSL applications Maury Wright

26 OUTDOOR LIGHTING

Regeneration throws light on Norman architectural

heritage Caroline Hayes

33 PROGRAMS

LED lighting progresses driven by lessons learned

James Brodrick, US Department of Energy

43 FOCUS ON

Auroralia Awards Maury Wright

53 OPTICS

Tertiary optics deliver benefits in SSL product

design Suleyman Turgut, Luminit LLC

59 SCIENCE

UV-LED advancements extend the promise in

curing Bill Cortelyou, Phoseon Technology

65 DESIGN FORUM

Simulation enables optimum LED streetlight

heat-sink design Djordje Zivanovic, BUCK d.o.o., and

Richard Ozaki, Mentor Graphics Corporation

68 LAST WORD

LED sources need to find a place in the recycling

stream Nigel Harvey, Recolight

Cover Story

Modern controls and solid-state lighting

enhance the features of Durham Castle

and Cathedral while reducing energy

usage. Specifiers were able to maintain

architectural integrity, mitigate light

pollution, and protect local wildlife. (See

p. 26; courtesy of Stainton Lighting

Design Services)

March

columns/departments

4 COMMENTARY Maury Wright

SIL talks foreshadow significant

LED revenue growth

9 NEWS+ANALYSIS

Red and warm-white LEDs

wash Rabat walls

GE Lighting and CRS

Electronics settle suit

Cree expands high-density COB family

Evolucia wins optics patent

Microchip acquires Supertex

Acuity announces EcoDrive

family from EldoLED

Lutron expands EcoSystem family

Sharp launches color-

tunable mid-power LEDs

Samsung LEDs target mobile devices

Osram adds color LEDs

for auto applications

19 FUNDING + PROGRAMS

CSEM announces EU-funded LASSIE-FP7

large-area SSL module project

ISSUE 68

1403leds_3 3 3/3/14 4:26 PM

Page 6: LED Magazine - March 2014

4 MARCH 2014 LEDsmagazine.com

commentary

At the 15th-anniversary Strategies in

Light conference held in Santa Clara,

California over February 25–27, Strategies

Unlimited reported that LED revenues hit

$14.4B (billion) in 2013 with the projection

for growth to $25.9B in 2018. There was mod-

erate growth in the 7% range from 2012 to

2013 but the forward projection calls for

double-digit growth over the next five years

driven by LED-based general lighting. Still,

some of the more interesting points were in

the details in terms of the types of LEDs to

be used and where they are made.

Strategies Unlimited analyst Katya

Evstratyeva said that in 2013, general light-

ing applications accounted for 30% of LED

sales — clearly becoming the technology and

market driver after edging into the domi-

nant position in 2012 (http://bit.ly/1cVaIPK).

The share of the LED market for general

solid-state lighting (SSL) applications will

hit 57% by 2018, according to the research.

Strategies Unlimited offered details about

suppliers to the LED lighting market and the

types of LEDs used in different types of prod-

ucts. For starters, a pie chart that segmented

where LEDs for lighting products are manu-

factured was surprising. The US accounts for

31% of those LEDs sold into lighting. Evstra-

tyeva didn’t detail the US sources but noted

that one particular company in the US has

had notable success in lighting.

The company behind the US ranking is

assuredly Cree. That company’s focus on the

lighting market with its LED offerings has

driven it to a dominant position in lighting,

whereas Cree is only the 6th ranked global

LED supplier by revenue. Moreover, Cree’s

aggressive move into lighting products —

most notably, retrofit lamps in the past year

— has helped drive LED revenue. Strategies

Unlimited estimates the value of the LEDs

supplied internally in the case of vertically-

integrated LED manufacturers. Japan at

21% and Korea at 15% were the next largest

sources of LEDs for lighting.

Meanwhile, Strategies Unlimited said

retrofit lamps will become the largest near-

term consumer of LEDs in SSL, and A-lamps

will lead the way despite the call for innova-

tive new form factors that fully leverage LED

sources. Evstratyeva said that in 2013 there

were 100M (million) LED retrofit lamps sold.

That sounds impressive until you consider

that there are 50B sockets installed globally.

In the lighting segments discussion, it was

the projected breakdown of the LED types to

be sold that perhaps was most surprising. In

recent years, we’ve heard about low-cost mid-

power LEDs taking over in lighting, and that

would seem an appropriate trend in the cost-

sensitive lamps market. But Evstratyeva proj-

ects that low-and mid-power LEDs combined

would, by 2018, only account for 35% of the

LEDs sold into lamps based on component

revenue. The actual number of components

shipped would tell a far different story.

Mid-power penetration will be greater

in commercial and industrial applications.

The mid- and low-power segment will

account for about 50% of revenue by 2018.

High-power LEDs will go from 50% in 2013

to 15% in 2018. But superhigh-power, which

includes chip-on-board (COB) LED arrays,

will represent 35% of the revenue in 2018.

Lower-power penetration will be driven by

linear applications such as ceiling troffers.

Those in the audience at Strategies in

Light surely saw opportunity in the many

presentations that the conference com-

prised. It will be a fun five years watching

the jockeying for leadership positions.

Maury Wright, EDITOR

[email protected]

SIL talks foreshadow significant LED revenue growth

SENIOR VICE PRESIDENT Christine Shaw

& PUBLISHING DIRECTOR [email protected]

EDITOR Maury Wright [email protected]

ASSOCIATE EDITOR Carrie Meadows

[email protected]

CONTRIBUTING EDITOR Caroline Hayes

[email protected]

MARKETING MANAGER Kimberly Ayer

ART DIRECTOR Kelli Mylchreest

PRODUCTION DIRECTOR Mari Rodriguez

SENIOR ILLUSTRATOR Christopher Hipp

AUDIENCE DEVELOPMENT Debbie Bouley

EDITORIAL OFFICES PennWell Corporation,

LEDs Magazine

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CORPORATE OFFICERS

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TECHNOLOGY GROUP

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SUBSCRIPTIONS: For subscription inquiries: Tel: +1 847 763-9540; Fax: +1 847 763-9607; e-mail: [email protected]; ledsmagazine.com/subscribe

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

Copyright © 2014 PennWell Corp (ISSN 2156-633X). All rights reserved. Contents of this publication may not be reproduced in any form without prior written consent of Publishers.

1403leds_4 4 3/3/14 4:27 PM

Page 7: LED Magazine - March 2014

DISCOVERING

LIGHTMore at Light + Building

2014

We bring quality to light.

Putting LEDs in the right light.

Instrument Systems Germany · Phone: +49 89 45 49 43 0 · [email protected] · www.instrumentsystems.com

SSL solutions from the world leader in LED measurement

Visit us at

LIGHT + BUILDING 2014

Frankfurt, Germany, March 30 - April 04, 2014Hall 4.1 Booth No. K89/90

Right from the start, we have been supporting the

LED industries with our measurement equipment.

You will also benefi t from this expertise in the new

Solid-State Lighting applications. Our solutions

combine highly precise spectroradiometers and

photometers with a complete family of gonio-

meters and integrating spheres.

Discover light with Instrument Systems.

www.instrumentsystems.com/ssl

light measurement

LGS 1000Goniophotometer

with new features

1403leds_5 5 3/3/14 4:27 PM

Page 8: LED Magazine - March 2014

6 MARCH 2014 LEDsmagazine.com

FEATURED events

| online

Editorial Digest

LED modules advance SSL

developments and light quality

http://bit.ly/1k9nm2e

Webcasts

SSL 2014: LED technology

advancements accelerate

the lighting revolution

http://bit.ly/1ptNplg

Understand LED driver design and dimming

techniques that can deliver optimal SSL products

http://bit.ly/1pqlJhe

White Paper

Materials Matter:

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LEDucation 8

March 18–19, 2014

New York, NY

Phosphor Global Summit 2014

March 26–28, 2014

San Diego, CA

Photonics21 Annual Meeting 2014

March 27–28, 2014

Brussels, Belgium

Light+Building 2014

March 30–April 4, 2014

Frankfurt, Germany

Asian Lighting Exhibition (ALEEX) 2014

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Guangzhou, China

Gulf LED Exhibition

April 22–24, 2014

Abu-Dhabi, United Arab Emirates

RadTech UV & EB Technology

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May 12–14, 2014

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Lightfair International 2014

June 3–5, 2014

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The LED Show

September 16–18, 2014

Los Angeles, CA

MORE: ledsmagazine.com/events

ADVERTISERS indexAamsco Lighting .........................................50

Autec Power Systems ..................................63

Carclo Technical Plastics .............................52

Cirrus Logic ...................................................2

Citizen Electronics Co., Ltd. .........................17

Cooledge Lighting .......................................13

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

E-Lite Semiconductor Inc. . ..........................58

ebm-papst Inc. ..............................................7

Edison Opto Corporation .............................42

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

FSP Technology, Inc. ...................................36

Future Lighting Solutions .......................24, 55

G-S Plastic Optics .......................................62

Global Lighting Technologies .......................15

Henkel ........................................................18

Indium Corporation .....................................31

Inpotron Schaltnetzteile GmbH ....................39

Instruments Systems GmbH .........................5

Inventronics (Hangzhou) Inc. .......................37

Ledlink Optics Inc. ......................................23

Lextar Electronics Corp. ..............................45

Luminis Devices ..........................................40

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

MBN GmbH .................................................14

Nichifu America Inc. ....................................67

Orb Optronix................................................64

Proto Labs Inc. ...........................................35

Radiant Zemax LLC .....................................25

Seoul Semiconductor Co. Ltd. .......................8

Shanxi Guangyu LED Lighting Co. Ltd. .........61

Sharp Devices Europe GmbH ......................20

Shenzhen Refond

Optoelectronics Co., Ltd. ..........................47

Shrewdd Marketing .....................................39

Signcomplex Limited ...................................38

TE Connectivity ...........................................49

The Bergquist Company ..............................29

The Korean Consulate General ....................12

Thomas Research Products ........................11

Underwriters Laboratories .....................41, 67

Zhejiang Baikang Technological Co., Ltd. .....32

Zhejiang LEDCOM Electronics Co., Ltd .........56

1403leds_6 6 3/3/14 4:27 PM

Page 9: LED Magazine - March 2014

The spotlight shines on efficiency.

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 with inaudible noise that’s

superior to passive heat sinks and raises performance while reducing the size of

the lighting fixture. With an industry-leading, German-engineered compact fan and

an American-designed assembly, ebm-papst can provide the most reliable solution

for your LED cooling problems. To find out more about custom Active Cooling

Solutions, visit info.ebmpapst.us/ActiveCooling. The engineer’s choice

1403leds_7 7 3/3/14 4:27 PM

Page 10: LED Magazine - March 2014

LED BRIGHTNESS THATíS

TOO GOOD

TO BE TRUE

Introducing the Acrich MJT 4040 High-Voltage LED

www.seoulsemicon.com

Using our patented Multi-Junction

Technology, the MJT 4040 offers

increased brightness and light density

perfectly suited for your next

outdoor LED application.

1403leds_8 8 3/3/14 4:27 PM

Page 11: LED Magazine - March 2014

+

LEDsmagazine.com MARCH 2014 9

viewsnews

LEC Lyon has supplied an LED lighting project in the his-

toric city of Rabat, the Moroccan capital that was recog-

nized as a world heritage site by UNESCO (United Nations

Educational, Scientific and Cultural Organization) in June

2012. In-ground LED spotlights bathe Rabat’s historic walls

in red and warm-white light with the ability to stand up to

harsh temperature and vibration extremes. Moroccan light-

ing specialist Electrimar handled the solid-state lighting

(SSL) design.

LED-based lighting is increasingly finding use in

UNESCO sites in part because of concerns over light pollu-

tion and the need for low-energy usage in older structures

with dated infrastructure. For example, we previously cov-

ered the Schréder project at the Grand Place in Brussels

(http://bit.ly/1m9Vw46).

The Rabat lighting was undertaken along with restruc-

turing of the Hassan II roadway that runs alongside the old-

town area of the city. The walls protect the south and west

sides of the city and were built in the late twelfth century.

The walls stand 8m high and the 1.5-km lit section features

architectural elements that the city chose to preserve and

highlight with the dual-color project.

“The walls encircle the old city of Rabat; the ones that are

enlighted today are the ones that are the most visible,” said

HERITAGE LIGHTING

Red and warm-white

LEDs wash Rabat walls

PACKAGED LEDs

Cree expands high-density

COB familyCree has announced the

CX A1310, CX A1850, and

CXA2590 COB LEDs with light-

emitting surface (LES) diame-

ters of 6, 12, and 19 mm, respec-

tively. The products are part of

Cree’s COB offering that the

company terms high density

and are designed to maximize the candela (cd) per dol-

lar for directional applications, as opposed to the stan-

dard-density products that are focused on maximum

lumens per dollar.

Cree first announced the high-density concept back

in September 2013 with the 9-mm CXA1520 that offered

double the output of the prior Cree LEDs in the same

size (http://bit.ly/1dpm7Eb). The new products extend

lumen output to beyond 13,500 lm at 5000K CCT and

to 11,500 lm at 3000K CCT. The 6-mm CXA1310, mean-

while, delivers flux in the 2000-lm range. Cree » page 10

BUSINESS AND IP

GE Lighting and CRS

Electronics settle suitGE Lighting has announced the settlement of a lawsuit that it filed in

December 2012 against CRS Electronics over patent infringement in

the area of LED lamp design. The GE and CRS lawsuit was waged over

US Patents 6,799,864 and 6,787,999. Those patents were focused on LED

retrofit lamp designs. Specifically, GE said that the

patents cover lamp heat-sink designs and technol-

ogies critical to replacing legacy lamps with LED-

based products. Terms of the settlement have been

kept confidential, but CRS will now pay for a license

to the patents in question.

“The 864 and 999 patents cover technology

important to the long-life operation of LED-based

lamps,” said Steve Briggs, general manager of global

product management for GE Lighting. “GE Lighting

is offering non-exclusive licenses under the 864 and

999 patents to interested parties. We are pleased

with this settlement, which demonstrates our commitment to defend-

ing GE Lighting’s intellectual property across the globe.” ◀

1403leds_9 9 3/3/14 4:30 PM

Page 12: LED Magazine - March 2014

10 MARCH 2014 LEDsmagazine.com

news+views

Rabat from page 9

Fouad Bahechar, presi-

dent of Electrimar. “Every 30m, the turrets

project over the street. We thought that this

rhythm was interesting to explore; that’s the

reason why we chose to use two colors —

warm white for continuity and red for relief.”

Challenges to the project included both

the environment and developing a system

that delivered accurate and uniform light.

The SSL products had to be shock-proof to

handle traffic in the area and also to oper-

ate in temperature extremes. Moreover, the

project required a provision allowing adjust-

ment of the beams.

Bahechar chose LEC 5716-Allevard spot-

lights that are designed to be recessed in

grade. He said, “LEC products are technical,

sturdy, and tailor-made.” The variations of

the product family deployed integrate 6–7

LEDs to light the 8m height. Additionally,

LEC delivered a custom lens to spread the

white light over the walls and the red light

on the turrets.

The specified fixtures can withstand

impacts of 20 joules and are rated IP-68 for

double protection against water ingress.

Moreover, LEC designed the fixtures to be

adjustable after installation. Indeed, the

fixtures can be adjusted without the device

being dismantled or the seal compromised.

LEC has been behind a number of Euro-

pean SSL projects where LED-based light-

ing was installed in a novel manner while

preserving the historic look and feel of a

site. For example, we covered a project in

Nîmes, France that included pedestrian tun-

nel lighting and roadway lighting mounted

in curbs (http://bit.ly/LImuCK). The Nîmes

project, which in aggregate involved lighting

manufacturers Comatelec, Ludec, Valmont,

and Philips Lighting in addition to LEC, was

ultimately selected as the first-place win-

ner in the Auroralia Awards for sustainable

lighting projects (p. 43). ◀

DRIVER ICs

STMicroelectronics driver IC and reference design enables networked street lights

STMicroelectronics has announced the

STEVAL385LEDPSR evaluation board and

reference design for intelligent LED-based

street light designs. The design includes the

STM8-microcontroller-based STLUX385A

digital power controller IC that can imple-

ment the SSL driver functionality and

enable networked LED street light designs

with a choice of interfaces and adaptive

control scenarios.

Many industry experts have suggested

that networked outdoor lighting is sim-

ply a necessity as the global population

expands and the population growth is espe-

cially acute in major cities. We covered such

sentiment at the 2012 Street & Area Light-

ing Conference expressed by Philips execu-

tive Niels Van Duinen in a keynote (http://

bit.ly/1pjpNjc). Speakers at the Strategies in

Light Europe 2013 conference voiced similar

opinions (http://bit.ly/1k5nu2w). LEDs save

energy but adaptive controls are needed for

maximum savings.

STMicroelectronics sees things similarly.

“Digitally controlled lighting is the key to

saving energy in outdoor installations,” said

Matteo Lo Presti, group vice president and

general manager for the Industrial and Power

Conversion Division of STMicroelectronics.

says that the

performance is industry best relative to the

LES sizes, and a smaller LES enables simpler,

lower-cost control of the beam with smaller

optical elements such as reflectors.

The LEDs are available across the range

of 2700K to 6500K CCT. Cree offers 80-CRI

products across the board, 70-CRI products

at the cool end of the spectrum, and 95-CRI

products at the warm end of the spectrum.

With the new product launch, Cree also

stressed a new way to consider LED perfor-

mance, and the match of LEDs to an appli-

cation, called optical control factor (OCF).

Essentially the metric comes down to perfor-

mance divided by surface area of the emitter,

whether the LED or LEDs under consideration

are in COB array or discrete form.

Paul Scheidt, product marketing man-

ager for LED components at Cree, discussed

applications and LEDs relative to OCF. He

said applications such as linear troffers can

benefit from mid-power LEDs with low OCF

that is a match for the broad beam spread,

diffuse light requirements of the applica-

tion. He said Cree’s mainstream CXA family

is also a good match to other applications

with diffuse light requirements such as BR

lamps and downlights.

The high-density COB LEDs are targeted

at high-OCF applications including direc-

tional lighting ranging from PAR/MR LED

replacement lamps to tracklights to even

low- and high-bay fixtures that need to focus

the beam. Primarily, the LEDs target appli-

cations that require maximum center beam

candle power (CBCP) and enable system per-

formance legacy sources can’t serve.

To illustrate the advantages of the new

products, Cree has assembled some pro-

totype light engines to which it compared

existing lighting fixtures and lamps based

on legacy sources. For example, Cree has

demonstrated a CXA1310-based engine

that delivers 31,000-cd CBCP and a 9° beam

at 15.4W. Scheidt compared that product to

a typical track fixture that uses a 44W Phil-

ips PAR20 ceramic metal-halide (CMH) lamp

that delivers 13,220-cd CBCP and a 10° beam.

In fairness, the Philips CMH lamp is 86

CRI and the Cree prototype is 82 CRI. But the

performance advantage of the LED option is

clear. Scheidt said that a quality track fix-

ture sells for $200 in high volume and the

lamp for around $20 with those prices dou-

bled if bought in individual quantity. He said

that the bill of materials for the LED light

engine was in the $34 range in high volume

including LED, driver, heat sink, and optic.

The track fixture includes a ballast and

that component is equivalent to the driver in

the LED light engine. But the point is that a

track luminaire priced in the $200 range can

easily accommodate the cost of the LED light

engine and deliver superior performance. ◀

MORE: http://bit.ly/1hpGVhW

Rabat from page 9

1403leds_10 10 3/3/14 4:30 PM

Page 13: LED Magazine - March 2014

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1403leds_11 11 3/3/14 4:30 PM

Page 14: LED Magazine - March 2014

12 MARCH 2014 LEDsmagazine.com

news+views

“ST’s new solution for LED street lighting

packs 25 years of experience in power

conversion into a single, future-proof

platform. As grids get progressively smarter,

cities will be able to control the streetlamps

to produce even greater savings because

all the key communications protocols are

already incorporated in the STLUX385A.”

The company’s reference design enables

SSL street light manufacturers to quickly

bring intelligent designs to market. STMi-

croelectronics will supply the design with

full schematics, a detailed bill of materials,

and the required firmware. The STLUX385A

IC can handle both the power-regulation

stage on the primary side of an AC/DC driver

along with implementing smart features and

adaptive controls.

Indeed, the STLUX385A IC integrates full

support for a DALI (digital addressable light-

ing interface) network link. The peripher-

als integrated with the microcontroller can

enable implementation of 0–10V analog con-

trols and also interface with a variety of sen-

sors. Digital communications facilities on

chip allow for a development team to add

Wi-Fi, ZigBee, and other network support

with external ICs.

The evaluation board allows development

teams to immediately experiment with SSL

system designs using a fully operational

driver. The design is capable of dimming

based on programmatic or sensor control.

Moreover, the design includes a power-factor

conversion regulator followed by a zero-volt-

age-switching resonant stage that together

with the STLUX385A compose the complete

LED driver functionality. ◀

BUSINESS AND IP

Evolucia wins optics patent

Evolucia has won a new US patent for the

Aimed Optics technology that it uses in

SSL products for outdoor applications.

Patent 8,635,049, “Light unit with light

output pattern synthesized from multiple

light sources,” was published on January

21, 2014 (http://bit.ly/1o0HK2D). As the

title implies, the Aimed Optics technol-

ogy is used to form the desired beam in

luminaires based on LED point sources

for applications such as the various IES

(Illuminating Engineering Society) defined

roadway beam patterns.

Evolucia has claimed that its optics tech-

nology offers better efficiency than compet-

ing optical technologies from other com-

panies. Most companies competing in the

outdoor space use total internal reflection

(TIR) lenses on each LED to form the beam

pattern (http://bit.ly/1k4eF5T). Evolucia

combines simpler optics and directional

LED mounting in outdoor fixtures.

“We aim the LEDs exactly where we want

the light to shine, which uses less energy to

create more light — a key point recognized in

the patent,” said Evolucia CEO and chairman

Mel Interiano. “In other words, the shortest

distance between two points is a straight line.

Our patented Aimed Optics technology sim-

ply uses that principle to its fullest. We don’t

need to redirect the light path with optics,

which creates inefficiencies.”

Microchip acquires SupertexMicrocontroller specialist Microchip

Technology has acquired analog and mixed-

signal IC manufacturer Supertex includ-

ing the latter’s LED driver IC technology.

The acquisition of Supertex could impact a

number of application areas, although SSL

is certainly a prominent one. Microchip

has offered limited support for LED-based

lighting applications through its microcon-

troller (MCU) and analog IC portfolio, and

the MCUs will be increasingly applicable as

intelligence is integrated into more lamps

and luminaire products.

“We are pleased to have Supertex become

part of the Microchip team,” said Steve

Sanghi, president and CEO of Microchip

Technology. “Supertex’s deep domain knowl-

edge in high-voltage analog and mixed-sig-

nal technologies, and strong position in the

medical, industrial, and lighting markets

complement many of Microchip initiatives

in these areas. We believe that combining

Supertex’s business with Microchip’s ana-

log business will enable significant syner-

gies and cross-selling opportunities.” ◀

MORE: http://bit.ly/1gwJ36M

1403leds_12 12 3/3/14 4:30 PM

Page 15: LED Magazine - March 2014

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Page 16: LED Magazine - March 2014

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DRIVERS

Acuity announces EcoDrive family from EldoLED

Acuity Brands has entered the OEM mar-

ket after purchasing driver-maker EldoLED

last year (http://bit.ly/1bFFpKp) and now

has launched the EcoDrive family under

the Acuity banner. For Acuity, the EcoDrive

launch also marks the commissioning of a

new high-throughput, surface-mount-tech-

nology production line that can yield 1 mil-

lion LED drivers and 5 million LED circuit

boards annually. Indeed, the EcoDrive driv-

ers come to market after Acuity added both

engineering and manufacturing resources.

“We have added significant engineering

resources to our solid-state lighting team

and expanded our electronic manufacturing

capacity,” said Mel Mendoza, Acuity’s

vice president of SSL. “With the rapid

transformation to LED lighting technologies,

we have made significant investments to

enable us to provide delivery of high-quality

electronic components to the industry.”

The new drivers target indoor applications

and are based on a digital-power-control

architecture that enables smooth dimming

down to 1% of full scale. Moreover, output

voltages are programmable and Acuity will

offer the family in a variety of form factors.

The products are key to Acuity expanding

its OEM sales. “We are excited about the Eco-

Drive being an integral part of Acuity Brands

lighting solutions, and even more excited

about the value it offers to our OEM part-

ners,” said Gilles Abrahamse, vice president

and general manager of the eldoLED division

of Acuity. EldoLED will showcase the prod-

ucts to the European audience at the upcom-

ing Light+Building trade fair. ◀

Lutron expands EcoSystem family

Lutron has announced the EcoSystem

5-Series LED driver family with support for

dimming of LED fixtures down to 5% with

control enabled by the company’s EcoSystem

lighting-network technology. EcoSystem is

an enhanced version of the DALI network

that enables control of lighting. Lutron offers

luminaires, control panels, sensors, drivers,

and other elements with EcoSystem inter-

faces (http://bit.ly/1e0AdLk). Moreover,

other luminaire makers including Cree and

GE Lighting offer EcoSystem as an optional

feature in some products.

The Series-5 drivers can allow any SSL

manufacturer to add EcoSystem support

to a luminaire. Lutron says the technology

can boost energy savings 60% through occu-

pancy sensing and daylight harvesting, and

1403leds_14 14 3/3/14 4:30 PM

Page 17: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 15

news+views

the driver is designed to help lighting spec-

ifiers deliver systems that meet stringent

green energy codes. The driver family sup-

ports loads up to 35W. The design includes

an on-board microcontroller that simplifies

lighting design and commissioning.

“The new 5-Series driver, which is rated for

50,000 hours of lifetime operation, lets speci-

fiers, contractors, and building managers eas-

ily accommodate change,” said Eric Lind, vice

president of specification solutions at Lutron.

“Spaces can now be easily rezoned without

rewiring during the design or commission-

ing phases, or throughout the building lifecy-

cle, making it an affordable, flexible solution

for reliably controlling LEDs.” ◀

PACKAGED LEDs

Sharp launches color-tunable mid-power LEDs

Sharp Devices Europe has announced the

Mini-Tiger Zenigata LED family that includes

emitters in two different CCTs, which allows

the components to produce light over the

range of 2700–6500K. Sharp will demonstrate

the compact 4.2×3×0.9-mm LEDs for the first

time at the Light+Building tradeshow. The

LEDs will enable tunable SSL products that

can enhance health and productivity.

The new LEDs add to the Zenigata fam-

ily with a much smaller LED in a surface-

mount-device (SMD) package. The Mini-

Tiger products are a departure from the

prior Zenigata-branded chip-on-board

(COB) LEDs. Indeed, the Mini Zenigata LEDs

announced last year are in a 12×15-mm foot-

print (http://bit.ly/1dpl2fE). As for a tunable

CCT, Sharp has previously offered that fea-

ture in larger COB LEDs, having launched

the Tiger Zenigata with a 17-mm LES back in

2012 (http://bit.ly/1fifQd6). That COB device

had visible stripes of different phosphor for-

mulations across the LES — presumably the

basis for the name Tiger. The new Mini-Tiger

Zenigata mid-power LED simply has side-by-

side emitters with different CCTs.

Mini-Tiger LEDs are designed to be driven

by dual constant-current power supplies

with each channel delivering 120 mA to

the LED that has a typical forward voltage

of 3.1V. For an SSL product to offer tunable

performance, the design will require some

local control to vary the relative drive cur-

rents to the two LED channels. Sharp has

suggested that a link such as DALI would be

typically used to connect a luminaire based

on the LEDs.

The 2700K emitter delivers 32 lm from the

120 mA drive current while the 6500K emit-

ter delivers 38 lm. Sharp said that the com-

bined CRI will be over 80 at a minimum. ◀

MORE: http://bit.ly/1hKHN5e

Samsung LEDs target mobile devices

Samsung Electronics has announced three

new families of packaged LEDs that tar-

get usage in mobile devices and debuted in

February at the Mobile World Congress in

Barcelona, Spain. The products include two

LEDs in a reflector-integrated package for

f lash applications, one LED in a f lip-chip

package for flash applications, and two side-

view LEDs targeted at edge-lighting mobile

device screens.

The ref lector-integrated devices are

designed to enable a wider field of view (FOV)

or wider beam angle for the camera flash in

high-end mobile devices. The wider FOV

improves picture quality. The integrated reflec-

tor design allows the LEDs to fit in a small foot-

print within the mobile device. Indeed, Sam-

sung said the reflector design includes optics

and diffusion features in the package.

Samsung supplies the ref lector-based

designs in a 3432 package that stands

1403leds_15 15 3/3/14 4:30 PM

Page 18: LED Magazine - March 2014

16 MARCH 2014 LEDsmagazine.com

news+views

1.8 mm high. The FH341A model delivers 165

lx at 1A and a minimum CRI of 80. The prod-

uct is due shortly in a new Samsung Galaxy

smartphone. The FH341B is even thinner at

1.4 mm and delivers 165 lx.

The flip-chip Flash LED is offered in a

smaller 2016 package and targets mid-range

mobile devices including products in smaller

form factors than the leading smartphones.

Samsung said the phosphor deposition tech-

nique using a cell-film technology improves

color deviation by 40% and the LED will come

in at a new lower price point relative to earlier

2016-packaged LEDs.

For screen-lighting, Samsung

has announced the MS062F

and MS082F LEDs. Both

of the devices are in

a 3810 package and

stand 0.6- and 0.8-

mm high, respec-

tively. The low profile

is crucial in allowing prod-

uct developers to mount the side-

view LEDs along the screen bevel.

Samsung is not alone in supplying side-

view LEDs. Seoul Semiconductor announced

0.6-mm side-view LEDs last March that it said

offered a 10% advantage in lumen output at

the time (http://bit.ly/1fii8ZL). ◀

MORE: http://bit.ly/MUn8xF

Osram adds color LEDs for auto applications

Osram Opto Semiconductors has recently

added new colored LEDs in product fami-

lies that target front-and rear-facing auto-

motive lighting applications. The company

has also said that it is the first LED manu-

facturer to transition red, orange, and yellow

indium-gallium-aluminum-phosphide

(InGaALP) LED lines to 6-in. wafers

— a move that should result in lower

component prices.

Osram has a portfolio of LED products

that target automotive applications includ-

ing the Oslon Black Flat LEDs designed to

deliver forward-facing white light for head-

lamps (http://bit.ly/1lfmCsy).

The Oslon Compact family

has a 1.5×1.9×0.7-mm foot-

print that allows the

LEDs to be packed

closely for light-

guide-based designs

used in many turn indi-

cators; the LEDs deliver 120 lm at

700 mA (http://bit.ly/1hpO5CP). That perfor-

mance level is achieved even at 100°C, which

the products may experience in the enclosed

chamber of an auto turn indicator or other

vehicular lighting function. At room temper-

ature the LEDs produce 140 lm.

Osram employs a blue emitter manufac-

tured using indium gallium nitride (InGaN)

epitaxial layers and a ceramic-based phos-

phor that converts the energy to yellow light.

Osram refers to the phosphor technology as

C2 for ceramic conversion.

The LEDs are made using a thin-film, flip-

chip architecture called UX:3. The process

includes removal of the growth substrate

after the epitaxial stage and flipping the chip

so that light is emitted from the bottom side of

the chip, which can maximize light extraction.

Moving to rear-facing applications, Osram

expanded the Black Flat family to include ver-

sions that can emit yellow and red tones that

are required for rear-facing auto lights and all

turn indicators Osram says that the expanded

family allows automotive engineers to cre-

ate complex tail lights using multiple LEDs

and powering the devices at different levels

to meet the various brightness requirements

associated with different operations such as

braking and reverse indication.

Also in the color LED sector, Osram said

it is the first to move to a 6-in. production

line. The company began conversion of blue

LED production for phosphor-converted

white LEDs starting back in 2011 (http://

bit.ly/1bFXw2E). The larger wafers allow the

production of more LED chips per wafer and,

assuming the manufacturer realizes accept-

able yield, lowers LED production cost.

“The demand for light-emitting diodes in

red, orange, and yellow continues to grow. We

are keeping pace with this demand by being

the first manufacturer in the world to switch

fabrication to 6-inch wafers — thereby also

expanding our capacity,” said Aldo Kamper,

CEO of Osram Opto Semiconductors. ◀

MORE: http://bit.ly/1jua51o

1403leds_16 16 3/3/14 4:30 PM

Page 20: LED Magazine - March 2014

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1403leds_18 18 3/3/14 4:30 PM

Page 21: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 19

+programs funding

The CSEM (Centre Suisse d’Electronique et de Microtechnique SA)

research organization based in Switzerland has announced the

LASSIE-FP7 (Large Area Solid State Intelligent Efficient luminaires)

project that over three years will seek to develop a new solid-state

lighting (SSL) planar module for high-end luminaires. The European

Union (EU) provided €3.15 million ($4.3 million) for the project that

will seek to use a hybrid of inorganic and organic technologies

thereby delivering the efficacy and long

life of high-power LEDs and the color-

tunable diffuse lighting of OLED panels.

CSEM implied that while LEDs are

succeeding in general lighting applica-

tions, the relatively small point sources

would always prove problematic in some

demanding architectural and professional

applications. OLEDs, meanwhile, remain

far too expensive for mainstream usage as

we covered in a recent feature article from

our February issue (http://bit.ly/Ou1Zvv).

CSEM hopes that the answer is a

hybrid approach. CSEM project coordi-

nator Rolando Ferrini said, “The devel-

opment of new hybrid SSL modules, com-

bining the extremely high efficiency and

long lifetime of inorganic LEDs with innovative color-changing coat-

ings based on reliable and stable organic fluorescent dyes, will pro-

vide new devices that go beyond the current technological bound-

aries of SSL.”

While the intent of the program is development of a module that

can be sold in a luminaire, the participants will also leverage the

work yielding innovative European-based SSL design and manufac-

turing capabilities. “The LASSIE-FP7 team includes a material sup-

plier, R&D players with simulation capability, processing experts,

component designers and manufacturers, integrators and testing

infrastructure, and last but not least a vendor of innovative-light-

ing systems,” said Ferrini.

In addition to CSEM, the participants include Fraunhofer of Ger-

many, the VTT Technical Research Center of Finland, Regent Light-

ing of Switzerland, BASF Schweiz of Switzerland, Gaiker of Spain,

Marsica Information & Technology of Italy, and Amires of the Czech

Republic. There are no details on how the participants will capital-

ize on the project individually, other than that Regent will build a

luminaire, but each of the organizations will gain skills and capa-

bilities that will help extend Europe’s capacity for delivering new,

innovative products, according to Ferrini.

The timeframe of the project is somewhat questionable with

the rapid commercial advancement of

both LED and OLED technology around

the globe. Tunable light sources should

be commonplace in three years and

planar lighting will be as well, whether

the implementation is based on LED

edge lighting, OLED technology, or some

other approach.

“We are conscious that the SSL

domain is evolving fast and some targets

need to be reached fast under the mar-

ket pressure,” said Ferrini. “However, on

the one hand LASSIE-FP7 targets a real

breakthrough in terms of performance,

which goes beyond the current expected

three-year roadmap for SSL.” He also

said that some of the interim develop-

ments of the research could be commercialized during the three-

year term of the project.

Ferrini was unwilling to disclose many more details about what

the module might look like or how it would be implemented, citing

the need to patent the developments. CSEM did say that the target

is the use of roll-to-roll manufacturing — a technique that has been

seen as one key way to lower OLED manufacturing costs. Current pla-

nar lighting products, including OLED-based designs and the LED-

based Cooper Halo Surface Downlight pictured nearby, are based on

a rigid glass plane. The CSEM target of using roll-to-roll manufactur-

ing implies a flexible substrate that could offer both lower cost and

new luminaire forms. For example, the European based Holst Cen-

ter has been working on such manufacturing on flexible substrates

(http://bit.ly/1fNQchi). But for now the success that has been achieved

in OLEDs has been in batch processing on glass. ◀

CSEM announces EU-funded LASSIE-FP7 large-area SSL module project

1403leds_19 19 3/3/14 4:30 PM

Page 22: LED Magazine - March 2014

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1403leds_20 20 3/3/14 4:30 PM

Page 23: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 21

interview | PHOSPHOR IP

Phosphor remains one of the least

understood business/technology

angles of white, high-power LEDs

and solid-state lighting (SSL); the state of

intellectual property (IP) in phosphors is

equally confusing. Indeed, many compa-

nies hold IP that directly addresses phos-

phor formulations and how they are applied

and many more patents are tangentially

related. The phosphor IP trail is often hid-

den among LED manufacturers by cross-

licensing agreements. Still, the SSL industry

needs a better understanding of phosphor

patent rights and how patents may or may

not impact product development and usage.

Back in mid 2012, we ran an IP-cen-

tric article specifically on remote-phos-

phor patents and IP holdings (http://bit.

ly/1dONfQZ). The authors at IP Checkups

identified Intematix and Cree as holding

major IP stakes in the area. Since Intematix

also supplies phosphors to LED manufac-

turers we took the opportunity to question

Julian Carey, senior director of marketing,

on the state of the phosphor IP space.

LEDs Magazine: Can you give us a

quick foundation as to the history of phos-

phor-oriented patents that are both directly

focused on LED products and perhaps that

are more general in nature if there is an

impact on SSL?

Julian Carey: High-brightness LEDs

were originally developed around the 1990s

by early producers of gallium nitride (GaN)-

based blue LEDs in Japan after researchers

from Nichia and a professor from Nagoya

University shared their formulation. The

combination of blue LED chips with YAG

(yttrium aluminum garnet) phosphor was

patented by Nichia in 1996 via US patent No.

5,998,925, commonly called the 925 patent.

As market research firm Yole Développe-

ment points out, while LED phosphor IP is

complex and rich with thousands of patent

families, only a few patents have provided

significant returns to their owners in terms

of market share, freedom of exploitation,

or additional revenue streams from royal-

ties. Some of those patents are on the verge

of expiring within the next 5 to 10 years —

most notably, Nichia’s 925 patent, which is

set to expire in 2017.

LEDs Magazine: Intematix announced

its green GAL (green aluminate) phosphor

back in 2010 and touted it as an alternative

to YAG and other licensed phosphor formu-

lations. Indeed, at the time the company spe-

cifically said that its customers — and we

assume that means customers making phos-

phor-converted LEDs or remote-phosphor

SSL products — would not require licenses

to Nichia or Osram phosphor patents (http://

bit.ly/1gXh5CS). Have you developed a cus-

tomer base for those patents among LED

manufacturers or has the primary usage

been in remote phosphor applications?

Carey: Today, Intematix is one phosphor

maker that is further addressing the

trend toward high-quality light with its

patented, advanced phosphor technology.

In addition to being the only company

that makes the patented GAL formulation,

Intematix patents also cover different

wide-spectrum green phosphors called

LuAGs (for lutetium-aluminum-garnet).

GAL generally offers a broader spectrum,

higher thermal stability, higher CRI, and

higher quality of light compared to LuAG

formulations, but owning IP that covers

Intematix expands phosphor development

and IP to meet demanding SSL applications

MAURY WRIGHT interviews Intematix executive JULIAN CAREY on the state of intellectual property in

the phosphor area, Intematix’s latest developments and patents, and applications from LEDs to

backlighting to remote optics.

Phosphor formulations such as those from Intematix are central to manufacturing LEDs.

1403leds_21 21 3/3/14 4:30 PM

Page 24: LED Magazine - March 2014

22 MARCH 2014 LEDsmagazine.com

interview | PHOSPHOR IP

both GAL and various LuAG formulations

enables Intematix to offer the more extensive

portfolio of broad greens and reds essential

to high-quality LED light.

Since the product introduction, GAL has

seen widespread implementation in LEDs

worldwide, which are its primary usage. The

performance of the material in terms of its

ability to reach high CRI, especially in combi-

nation with red, and its thermal stability has

driven adoption. These same characteristics

make it valuable in remote solutions as well.

LEDs Magazine: What has driven new

phosphor developments beyond IP issues?

Have the needs for better color quality and

better color consistency over time been a

driving factor? What about lower costs?

Carey: Growth in LED-based lighting in

North America is estimated to average 38%

annually between 2012 and 2016, according

to a recent McKinsey & Company report. Now

that we are seeing LED use transition into

general lighting, thanks to reduced pricing

and accessibility of products with LED tech-

nology, quality of light has become the pre-

dominant requirement. This, in turn, has led

to a demand for more advanced phosphor

solutions and a much more complex mixing

strategy. Generally, a two- or even three-phos-

phor strategy is needed to attain high CRI and

high R9, an indication of how well the light

shows deep, saturated shades of red.

In addition to mixing strategy, phos-

phor solutions for general lighting require

a high degree of ruggedness. They are based

on very tough molecular structures and are

lasting for upwards of 50,000 hours. Thus,

today’s primary lighting phosphor options

are green aluminate (such as GAL), red

nitride, and YAG. Not only do these mate-

rials have long lifetimes, but they also have

high thermal stability, independent of life-

time. For example, if you go as high as

200°C with GAL, you will only lose a very

small degree of brightness — this very high

degree of stability means that manufactur-

ers can drive their LEDs harder and realize

lower costs using fewer LEDs.

LEDs Magazine: While this isn’t a patent

question exactly, a few years back there was

great concern over the availability of rare

earth materials needed for phosphors and

the possibility that China would limit export

of those elements. We have heard little about

the problem of late. Has that situation sta-

bilized? Did the development of new formu-

lations help in anyway to avoid a shortage?

Carey: Base materials of most phos-

phors are very plentiful, but they have addi-

tives or dopants, and those are where you

find these rare earth materials. So while

the amount of rare earth materials in each

of these phosphors varies, it’s usually very

small, but it can be more significant in some.

Despite some of the news clippings that have

appeared over the last few years, we have not

seen any effect of rare earth pricing or insta-

bility in the LED market overall. And the rea-

son for that is two-fold. First, the amount of

phosphor generally used in LED applications

as a fraction of the lumens produced is very

small. It just doesn’t contribute that much to

the overall solution cost. That’s in contrast

with fluorescent. Fluorescents have multi-

ple grams of phosphors in each product, and

there are also different formulations in those

tubes. Some of the increase in pricing from

China that we saw a few years ago actually

did affect the fluorescent market. The sec-

ond major reason is even though there was

instability triggered by China’s actions, now

we’re seeing additional sources pop up all

over the world. Since it’s really not a monop-

oly anymore, we’re seeing a much more bal-

anced market for these raw materials.

Generally, the improvements in LED tech-

nology, phosphor technology, in addition to

the semiconductor technology, the driver

electronics technology, all of that is going

to far outrun any issues that we are going to

see in rare earth supply.

LEDs Magazine : Intemati x just

announced the award of a new red nitride

patent back in December and another cov-

ering similar technology back in September

2012. What technology is covered by those

patents, and is that technology already being

deployed in packaged LEDs and/or remote-

phosphor optics? Has there been more recent

innovation in green phosphors after GAL?

Carey: Red nitride phosphors play a cen-

tral role in extending the color range of LED

applications like general lighting and dis-

plays including TVs, monitors, and tablets.

Intematix red nitrides combined with GAL

green phosphors, phosphor combinations

covered by the company’s previously issued

patents, enable near-perfect color rendering

up to 98 CRI. The XR red nitride also leads

in color stability with less than perceptible

2-MacAdam-ellipse measured color shift in

accelerated aging testing. This performance

results in lighting applications with long-

term color quality and consistency.

The ChromaLit linear remote-phosphor optic from Intematix.

Generally, a two- or even three-phosphor

strategy is needed to attain high CRI and high

R9, an indication of how well the light shows

deep, saturated shades of red.

1403leds_22 22 3/3/14 4:30 PM

Page 26: LED Magazine - March 2014

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Page 27: LED Magazine - March 2014

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interview | PHOSPHOR IP

LEDs Magazine: We understand, as you

said, that some of the most basic patents in

the phosphor area will expire in the coming

years. As we discussed, the Nichia 925 patent

will expire. How will such an event impact

the phosphor industry? Most of the major

LED manufacturers have cross-licensing

deals in place so it seems the impact there

might be minimal. But could it shake up the

industry in other ways?

Carey: The expiration of the Nichia pat-

ent will remove a significant barrier and

will allow broader use of the YAG materi-

als covered by the patent. Patent activity

remains strong and it is now focused on

emerging compositions, mostly addressing

the need for more efficient and cost-effec-

tive red and green phosphors to be used in

display and general lighting applications.

Differentiation opportunities remain, and

the development of any new compositions

with disruptive potential could still greatly

benefit its inventor.

LEDs Magazine: In the area of remote

phosphor there have been continuing ques-

tions as to whether your customers making

SSL products with your ChromaLit optics

might need license agree-

ments with other compa-

nies. Cree in particular has

said that any company mak-

ing remote phosphor lamps

or luminaires needs to have a

cross-licensing agreement in

place. You have insisted that’s

not the case. What is your

stance and how are you stand-

ing behind your customers?

Carey: Intematix is very

confident regarding its remote phosphor

IP and stands behinds its remote phosphor

products. In fact, not only will Intematix

cover legal costs in the event of an infringe-

ment litigation regarding its products,

but it will also take responsibility for the

defense of any such litigation.

LEDs Magazine: Also with regard to

remote phosphor, your latest products in the

linear application segment have a coating

that allows the products to appear white in

the off state and therefore potentially appeal

more to lighting designers/

specifiers. What is the IP

behind that technology? Is

that a phosphor story or one

based on yet another type of

materials? Do you expect to

patent that technology?

Carey: W hi le we do

have patents covering lin-

ear remote phosphor, the IP

pertaining to the off-state

appearance of our new lin-

ear product would fall more into the trade

secret area. The way the technology con-

ditions the light going into the optic dif-

fers from that exiting, which is why it shows

good appearance without affecting light

output too much. Different types of inno-

vations may be best served in our business

with different IP strategies and these are

matters we consider to great extent.

Julian Carey, Intematix

1403leds_25 25 3/3/14 4:31 PM

Page 28: LED Magazine - March 2014

26 MARCH 2014 LEDsmagazine.com

In the north of England, the town of

Durham is guarded by dual, imposing

monuments — its castle and the city’s

cathedral. As the 25th anniversary of the

castle and cathedral’s status as a United

Nations Educational, Scientific and Cultural

Organization (UNESCO) World Heritage

Site approached, a regeneration of the light-

ing scheme was planned. The aim was to

enhance the aesthetics of the Norman mon-

uments, highlight the architectural features,

subtly distinguish the two buildings when

viewed from a distance, vary lighting for spe-

cial events while protecting the local wild-

life, and significantly reduce energy costs.

History

William the Conqueror commissioned the

castle to be built in 1073, to defend the set-

tlement on the peninsula along the River

Wear. It became the residency of Bishops

of Durham, and buildings were added and

altered to suit the needs of the day. Across the

green is the cathedral, which dates from 1093

and is acknowledged as the largest example of

Norman architecture in England. It is the only

cathedral considered to retain most of its con-

temporary Norman craftsmanship and one

of the most important examples in the UK.

The World Heritage Site monuments

were lit by large, exterior, high-power-pro-

jector high intensity discharge (HID) flood-

lights placed at ground level that had been

installed in the 1960s. They were deemed

to be at the end of their serviceable life

and also outmoded. There was no attempt

to conceal them and they gave a f lat wash

of light across the buildings, rather than

accentuating features. In addition, the

lamps and the control gear used were not

energy efficient.

A new scheme was required to reflect the

modern role of the castle and cathedral,

where nighttime visitors are encouraged,

and where special events can have a custom-

ized lighting system to add aesthetic

appeal or highlight areas of interest.

Another requirement was to save energy —

a target of 33% reduction was set — as well

as to reduce light spill for the student

accommodation quarters in the castle, and

also for the Pipistrelle and Natterer bat pop-

ulations locally.

CAROLINE HAYES is a contributing editor with

LEDs Magazine.

CAROLINE HAYES examines the regeneration of the lighting scheme at a UNESCO World Heritage Site in

England, where modern controls and solid-state lighting are used to enhance the building’s features

while project specifiers remain sensitive to the architectural integrity of the monument as well as

potential light pollution concerns.

outdoor lighting | ARCHITECTURAL

Regeneration throws light on Norman architectural heritage

The LED-lit entrance

to Durham castle.

1403leds_26 26 3/3/14 4:31 PM

Page 29: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 27

Landmark lighting

Stainton Lighting Design Services and Urbis

Schréder designed the scheme, which was installed

by AK Lighting and Signs. Anthony Smith, director,

Stainton Lighting Design Services explained that

the plan was to change the viewing experience dur-

ing the hours of darkness and to provide a landmark

lighting scheme, which would stimulate the area’s

nighttime economy.

There was also some confusion among visitors

who viewed the castle and cathedral from the city

below — from certain viewpoints, the cathedral

tower appeared to rise from the castle. A way to

distinguish the two buildings, using the lighting

scheme, was added to the plan.

“A primary aim was to maintain a subtle, but

observable contrast between the color temperature

of the castle and cathedral,” said Smith. This would

allow the site to be viewed as a coherent World Heri-

tage Site, while allowing the individual buildings to

retain their identities. To offer an alternative view-

ing experience by day and night was another prior-

ity, which required luminaires to be located unob-

trusively where they could not be easily seen. The

floodlights were placed closer to the buildings than

the ones they replaced, between 1 and 3m (or 3–9

ft) from the buildings. The closer positioning also

eliminated the need for additional window reveals

The new solid-state

lighting system

accentuates some of

the historic stonework

at Durham Castle.

1403leds_27 27 3/3/14 4:31 PM

Page 30: LED Magazine - March 2014

28 MARCH 2014 LEDsmagazine.com

as the new system produced less light spill

into the buildings’ windows. This was a

particular benefit in the castle keep and the

parts of the cathedral that are used for stu-

dent accommodation.

The proximity of the customized Urbis

Schreder Neos 1, Neos 2, and Noctis 225 LED

floodlights and bespoke Philips eW Reach

floodlights serve to highlight the fabric and

fine masonry work of both buildings without

being visible themselves. Paul Johnson, Urbis

Schreder’s regional sales manager, north of

England, explained the pains that the project

went to in making the lighting unobtrusive,

with the Neos being coated in a color that was

specifically selected to match the stonework

against which it was positioned. Similarly,

the Noctis floodlights were positioned flush

into the ground so they could light up specific

areas without being visually intrusive. The

castle courtyard, Johnson added, is an area of

high traffic and so again, unobtrusive lighting

was a requirement for the free-flow of pedes-

trian foot traffic. High-power Cree XP-E and

XR-E LEDs were used in the floodlights, with

seven optic types provided by Carclo.

Each light was tailored to where it was to

be located. Johnson declared, “All Neos lights

are, to some degree, bespoke, but none as

bespoke as this — 95% was non-standard,”

he said, referring to the individual light com-

bination of the 64 LEDs used in each light.

Stainton specified the combination of wide,

medium, and narrow, and horizontal and

vertical beams, including those with 90˚ for

a low horizontal line or a long vertical line on

particular areas. For each floodlight, a spe-

cific position was designated, with a specific

lens combination.

Despite the options and configurations,

all variances in color temperature were

within 100K. The customization was also

practical. Smith points out that although

the specification for each luminaire was

bespoke, the selection of LEDs will allow

replacements to be provided with the exact

same characteristics.

Some of the detail that the lighting made

more prominent was commented on by long-

term members of castle staff, who reported

that they had not noticed some of the inter-

esting stonework features before.

Part of the design concept regarding dis-

tant views of the buildings was to provide

a subtle but observable contrast between

the color temperature of the castle and the

cathedral. Two color temperatures were

selected for each building — 3000K and

The Norman architecture

of Durham Castle and

Cathedral, seen from the

city of Durham below.

Less light spill throughout the property

benefits the students boarding in the

castle keep quarters during term time.

1403leds_28 28 3/3/14 4:31 PM

Page 31: LED Magazine - March 2014

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Page 32: LED Magazine - March 2014

30 MARCH 2014 LEDsmagazine.com

outdoor lighting | ARCHITECTURAL

3500K for the castle, and 3500K and 4000K

for the cathedral. “The variance in color

temperatures on each building offers con-

trast and depth to the abutment areas,” com-

mented Smith. “However, as the main color

temperatures are 3000K on the castle and

4000K on the cathedral, the color difference

of 1000K is still evident when the buildings

are viewed from a distance.”

Masonry preservation

The historical nature of the buildings, parts

of which stood on consecrated ground,

meant that great care had to be taken with

situating the luminaires. A key planning

constraint, reveals Smith, was that the

existing cable network was to be reused

wherever possible and, where clipped

cable was replaced, the fixing holes had

to be reused. Although 46 luminaires were

removed and more than 250 installed, no

new holes were able to be drilled into the

fabric of either building, meaning that

cable power or control had to use exist-

ing cable routes. There are only two loca-

tions where a luminaire has been set in an

existing location. The use of lead P-Clips

throughout was specified, and these were

manufactured by contractor AK Lighting

and Signs specifically for the project. This

seamless positioning all had to be achieved

despite the 500% increase in the number of

luminaires used throughout the buildings.

The archaeological heritage also meant

that there was a risk of finding buried arti-

facts that could cause costly delays. This was

another reason to use only existing cable

routes or previously undisturbed ground.

Equipment was limited to being buried

300 mm below ground level. Ground-

work was therefore undertaken early

in the installation phase to minimize

the impact of any archaeological finds. There

were constant archaeological checks, in case

any articles of interest were found. As tes-

timony to the care taken, more than 1 km

(or more than 3000 ft) of new underground

cable was installed — the majority within

the cathedral’s medieval graveyard — with-

out any delays to the project.

Cabling and luminaires on the roofs of

both buildings represented a particular

challenge. A robust platform was needed to

mount each luminaire but also had to pro-

vide termination control and power circuits.

The platform also had to be unfixed so it

could be moved for repairs to the lead roof-

ing; it had to be heavy enough not to shift

or tip in the wind, but light enough to be

taken up to the roof manually, as a crane or

similar was not practical in this case. The

solution was to carry component parts up

Close but discreet LED-based floodlights

illuminate the Norman architecture that

inspired later Victorian-Gothic design at

Durham Castle.

1403leds_30 30 3/3/14 4:31 PM

Page 33: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 31

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to the roof and assemble the roof-mounted

luminaires there. As a result, no part

weighed more than 20 kg (approximately

44 lb). In all, eight mounting arrangements

were used. The design was also used for four

lanterns in the courtyard, which required

mounting height of 1.4m (approximately 4

ft, 8 in.) and 0.5m (approximately 1 ft, 7 in.)

outreach from a free-standing bracket.

Wildlife

Another vital part of the project was to

preserve the wildlife around the area. A

bat survey was undertaken and identified

three existing roosts for bats. Most of the

bats around the site are Pipistrelle bats but

there are also Natterer bats, which are rel-

atively rare and which forage in trees and

vegetation. Both species are characterized

by roosting in the crevices of old buildings.

To respect the wildlife, no roosts were

lit and foraging sites or commuting routes

were not lit directly. In these areas, timers

and movement sensors were used to switch

lighting on 90 minutes after sunset and off

90 minutes before sunrise.

The LED lighting used high output bins

with low or nonexistent emission of ultravi-

olet (UV) or blue light to mitigate the envi-

ronmental impact of the scheme. Trees

and ground cover were not lit and exist-

ing lighting of trees and ground cover was

removed. Where lighting was necessary, it

was directed and featured low spill. A close

offset approach to lighting buildings avoided

unnecessary spillage. Louvers and glare

guards were fitted, as appropriate, to lumi-

naires to reduce spillage.

An ecologist inspected the final, installed

scheme and the design was commended for

its ecological considerations.

Lighting control

One of the main aims of the original plan

was to design a control system that could

reconfigure the lighting for specific events.

Rather than a hard-wired system, which

would require new cable routes, a partly

wireless DMX (Digital Multiplex) system

was decided upon. This is one of the most

common protocols used with LED technol-

ogy and offers control and flexibility, says

Smith. Johnson believes this is the first part-

wireless DMX implementation.

Luminaires were grouped into zones that

connect wirelessly to the main DMX control-

ler. Each zone has a DMX receiver, which uses

a traditional cable link between the lumi-

naires to form the DMX network. A problem

encountered in constructing the wireless sys-

tems was that the building did not always lend

itself to an ideal line of sight between trans-

mitter and receiver. Some of the walls are 2m

(6 ft) thick. The radio signals, says Johnson,

were sent over the building and around with

repeaters and aerials. Radio surveys verified

the prime locations for the two transmitters

and five receivers used in the wireless system.

Remote access to the DMX controller was via

the LPC1 lighting controller from Pharos.

It has 512 channels and real-time control of

playback selection and lighting levels for light-

ing sequences and automation. This was also

adapted by Urbis, who built the housing for the

drives and control gear.

As a result, special events can have a spe-

cific lighting sequence. There are five to six

programs set in the control “HQ” sited in

one of the cathedral offices and the porter’s

lodge in the castle, but, says Johnson, for

“serious slideshows, other sequences can

be programmed via a PC to produce color

schemes and to highlight particular areas.”

One of the main causes for celebration

of the project is that it was awarded third

place in the Auroralia 2013 Best Initiatives

in Urban and Sustainable Lighting category

for its energy savings (p. 43). Despite more

luminaires being used than in the original

lighting scheme, the target of 33% energy

savings was surpassed, with an annual

energy consumption reduction of 78%.

Smith adds that even if the scheme used the

same switching protocol as the original, it

would achieve energy savings of 60%. The

final installed lighting will save approxi-

mately £18,500 (around $30,360) per year

in energy costs at today’s prices, he says.

Despite more luminaires being used than in

the original lighting scheme, the target of 33%

energy savings was surpassed.

1403leds_31 31 3/3/14 4:31 PM

Page 35: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 33

programs | DOE SSL

Solid-state lighting (SSL)

has made impressive prog-

ress over the past decade,

emerging as a promising new tech-

nology that could fundamentally

alter and improve lighting systems,

and significantly lower energy use

and costs. Benefiting from lessons

learned from the market introduc-

tion of compact f luorescent lamps

(CFLs) in the 1980s and 1990s,

actions taken by the US Department

of Energy (DOE) in Gateway, Caliper,

Lighting Facts and other programs

(Fig. 1); energy efficiency programs;

and standards organizations have

helped industry avoid some of the

problems that plagued CFL mar-

ket development. Still, the lighting

industry faces challenges in the SSL

transition and can continue to ben-

efit from lessons learned in the early

stages of SSL deployment.

Efforts by the DOE and other

organizations have positively

impacted the experience of LED-

lighting adopters. Indeed, the adop-

tion of LED lighting is happening far

faster than did the adoption of CFLs,

although not nearly as fast as some

consumer electronics technologies

(Fig. 2). The success is in part due

to standardized testing, minimum

performance and reporting requirements,

and publication of testing and demonstra-

tion results that have made it more difficult

for poor-performing SSL products to remain

on the market, and rewarded manufacturers

whose products perform well.

Looking ahead, however, the full perfor-

mance and energy savings potential of SSL

is far from realized or assured. With that

in mind, the DOE’s new report, “Solid-state

lighting: Early lessons learned on the way to

market," analyzes actions taken thus far and

identifies challenges, new lessons, and their

implications for the future. The

result is a compilation of analysis

and recommendations for consider-

ation by manufacturers, standards

organizations, energy-efficiency

programs, retailers, specifiers, and

other stakeholders — intended to

stimulate further discussion and

to aid in the continuous course

corrections needed to achieve SSL

technology’s full potential. The

report is available online at www.

ssl.energy.gov/tech_reports.html,

and we will examine some of the

key lessons here.

Lesson 1: Rigorous testing require-

ments adopted in the early days of

SSL development were necessary to

counter exaggerated claims of per-

formance by some manufacturers,

but they eventually led to unreason-

ably high testing costs.

The exploding number of prod-

ucts and product variations com-

ing to market has created a test-

ing burden that can boost product

prices and slow product introduc-

tions, which in turn can slow mar-

ket adoption and associated energy

savings. Family grouping policies

have been the primary means used

by energy-efficiency programs for

addressing the testing burden issue.

The voluntary qualification and listing

groups — such as the DesignLights Consor-

tium (DLC), Energy Star, and DOE LED Light-

ing Facts — should consider increased coor-

dination to continue to reduce the testing

burden on manufacturers, while maintaining

the integrity of product data through random

LED lighting progresses driven

by lessons learned

SSL uptake is happening much faster than that of CFL products, reports JAMES BRODRICK of the

US DOE, but a new report uses lessons learned to outline steps the industry should take to move

forward more rapidly.

JAMES BRODRICK is the lighting program

manager at the US Department of Energy.

FIG. 1. Shown is an example US DOE Gateway installation

with solid-state lighting from Spring City Electrical in New

York's Central Park.

1403leds_33 33 3/3/14 4:31 PM

Page 36: LED Magazine - March 2014

34 MARCH 2014 LEDsmagazine.com

Years since market introduction

Market share (% of units)

3 4 50 1

1986: After 6 yearson the market, CFLshad only reacheda penetrationof <0.1%

CFL

1980: Philips releasesfrst commercial CFL

2007: LSG releasesfrst viable LEDreplacement bulb

LED

Smartphone

2013: After 6 yearsLEDs have reacheda market share ofover 4%

2 6

8

7

6

5

4

3

2

1

0

Driver(power supply)

52%

Housing31%

LED package10%

Driver(control circuit)

7%

programs | DOE SSL

verification testing. In addition, the

lighting community should con-

sider continuing to seek methods

and strategies to reduce the overall

testing burden on manufacturers,

as confidence in LED performance

continues to increase.

Lesson 2: Despite the promise of

long life, there’s no standard way

to rate the lifetime and reliability

of LED lighting products.

Variability in lifetime and reli-

ability of similar products needs

to be reduced to improve mar-

ket adoption of LED products.

There are many sources of fail-

ure in SSL products that must

be accounted for (Fig. 3). Uncer-

tainty is slowly being reduced, as efforts

are made to standardize methods for pre-

dicting lifetime and reliability. Standards

developers are working on new tools and

metrics, some of which will still be limited

in their usefulness, but these tools and met-

rics are needed to address this challenge.

Some manufacturers are providing longer

warranties for products serving key applica-

tions and market sectors, which represents

another way to overcome uncertainty. Inno-

vative product designs and increased use of

lighting controls may further complicate the

measurement and reporting of LED product

lifetime and reliability in the near future,

and all market actors need to work together

to explore the effect of such features on life-

time and reliability, as well as educate users.

Lesson 3: Although specifiers prefer com-

plete families of products, the rapid evolu-

tion of LED technology presents a challenge

to manufacturers in creating and maintain-

ing complete product lines.

Specifying families of luminaires allows

for a consistent look and feel throughout

a space and can also standardize mainte-

nance and spare parts. But manufactur-

ers sometimes lack the time to develop full

product ranges, or find it difficult to keep

products consistent with one another when

LED packages and drivers are changing so

rapidly. Without the option of product fam-

ilies, some specifiers may have trouble using

LED products across their projects.

Manufacturers should consider providing

a range of lamps or luminaires with similar

appearance, but with different photometric

performance. When an LED lighting product

is superseded by one with greater lumen out-

put, manufacturers should consider keeping

both in the product line. Developing one or

more forms of relative testing standards may

help manufacturers manage the cost of test-

ing product families.

Lesson 4: The range of color quality avail-

able with LED lighting products, and the

limitations of existing color metrics, may

confuse users.

While the availability of LED products

with a range of color qualities may be an

asset in one sense, the variability also

presents a number of challenges. Address-

ing these challenges will require a range

of coordinated industry efforts. Retailers

should continue their efforts to provide

clear information regarding color quality,

especially the difference between CCTs.

Efforts to improve the consistency of infor-

mation on product packaging should also

continue, and industry should establish

effective color communication tools to sim-

plify product selection.

At the same time, the lighting research

community should consider establishing

performance criteria for color rendering that

will ensure acceptability to a majority of

users. Standards organizations should con-

sider establishing tighter tolerances for chro-

maticity bins, to reduce product-to-product

variability at the same CCT, making it eas-

ier to specify various LED prod-

ucts in the same space. Revised,

new, or additional color rendering

metrics are needed to accurately

characterize the color rendering

capability of all light sources.

Lesson 5: The color delivered

by some LEDs shifts enough over

time to negatively impact adop-

tion in some applications.

The ability of LED lighting

products to maintain chroma-

ticity over long lives has been

demonstrated by the DOE L Prize

winner, but not all products per-

form at that level, and perfor-

mance can vary significantly

(Fig. 4). Color stability measure-

ment and prediction methods are needed to

enable performance comparisons between

LED lighting products. There’s a need for

energy-efficiency programs and product

information qualification standards that

include color stability metrics.

Efforts to establish new methods and met-

rics for color stability assessment should

continue. With standards and metrics, color

shift can rightfully be included in a yet-to-

be-developed comprehensive lifetime rating

FIG. 2. The uptake of LED lamps is much steeper than it was for

CFLs but trails the pace of consumer electronics products such

as mobile phones.

FIG. 3. The chart depicts the distribution

of 29 failures over 34 million operating

hours for one manufacturer’s family

of LED outdoor luminaires (source:

Appalachian Lighting Systems). Because

LEDs are just one component out of

many that can cause failure, a DOE-led

industry working group recommends a

systems approach to solid-state lighting

lifetime and reliability.

1403leds_34 34 3/3/14 4:31 PM

Page 37: LED Magazine - March 2014

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Page 38: LED Magazine - March 2014

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programs | DOE SSL

for LED lighting products. Manufacturers

and related industry committees should

continue to share test methods and data for

use by standards organizations, and these

organizations should consider incorporat-

ing the new knowledge generated into stan-

dards for color stability.

Lesson 6: Some LEDs f licker noticeably,

which may negatively impact adoption in

some applications.

Whereas conventional lighting technolo-

gies exhibit flicker in a fairly similar manner

that in many cases can be remediated with

appropriately designed ballasts, there is sig-

nificant variation in flicker for LED sources.

Standards organizations should consider

developing a measurement procedure for

flicker and a flicker metric that accounts for

frequency, so manufacturers can communi-

cate product performance (Fig. 5).

Manufacturers should consider evaluat-

ing and communicating the flicker perfor-

mance of their products both at full output

and when dimmed, accounting for depen-

dencies on the selection of control equip-

ment if applicable. The lighting research

community should consider conducting

research to establish thresholds for detec-

tion of (and perhaps objection to) flicker, risk

of neurological impacts, and degradation in

task performance for different applications.

Lesson 7: LEDs can cause glare, which

may negatively impact adoption in some

applications.

FIG. 4. A new lamp and an identical product after 4000 hours of operation show what

would be unacceptable color shift in many applications.

1403leds_36 36 3/3/14 4:31 PM

Page 40: LED Magazine - March 2014

programs | DOE SSL

Some of the glare issues with SSL have

been caused or exacerbated by the drive

to increase lighting output (e.g., by using

higher-output LEDs) and reduce cost (e.g.,

by using fewer LEDs), so one challenge in

addressing glare will be finding the bal-

ance between potentially competing goals.

The industry should continue working on

developing LED lighting solutions that

don’t increase glare relative to incumbent

technologies. DOE and research organiza-

tions should consider routinely including

glare assessments in product and applica-

tion evaluations and demonstrations.

Where a standard glare assessment meth-

odology isn’t available, these organizations

could work toward establishing new meth-

ods and metrics for glare assessment. Man-

ufacturers should continue to optimize their

use of optical solutions that reduce source

luminance, especially for applications where

the incumbent light source is much lower

in luminance than a typical LED source.

Energy-efficiency programs should consider

the implications of glare control when estab-

lishing efficacy standards for products.

Lesson 8: Achieving high-quality dimming

performance with LED lamps is difficult, but

the situation is improving.

While there’s no standard definition of

“dimmable,” the ability of all incandescent

sources to dim smoothly down to light lev-

els below 1% serves as the unofficial bench-

mark, and the comparatively poor dimming

performance of many LED lamps is limiting

their adoption. Retailers, manufacturers,

and organizations promoting the purchase

of dimmable LED integral lamps should con-

sider increasing their education efforts in

this area, alerting buyers to potential dim-

ming problems and working together to

develop better, clearer, and more consistent

means for communicating dimming guid-

ance to buyers.

Industry should consider developing

LED lamps capable of high-performance,

incandescent-like dimming with high effi-

cacy over the dimming range, and should

improve predictability of dimming perfor-

mance for specifiers and buyers. In addition,

industry should continue the development

of advanced dimming circuitry compatible

with phase control, as well as forward-look-

ing standards for phase-cut dimmers and

lamps, and should continue developing and

promoting alternative approaches that have

the potential to avoid many of the compati-

bility issues inherent to phase control.

Lesson 9: Greater interoperability of light-

ing control components and more sensible

specifications of lighting control systems

are required to maximize the energy sav-

ings from LED lighting.

The controllability of LEDs significantly

increases the potential for energy savings.

LED technology is poised to bring high-per-

formance, low-cost control of output level

and color to many lighting applications

for the first time. Integrating lighting con-

trols with a communication network offers

1403leds_38 38 3/3/14 4:31 PM

Page 41: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 39

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FIG. 5. Percent flicker and flicker index are metrics historically

used to quantify flicker, but standardized flicker measurement

procedures are not yet in place to ensure appropriate

comparisons of reported values for LED products.

additional opportunities to provide value and perhaps save money

and additional energy. The ability to track energy use and report

failures can reduce maintenance costs and save even more energy

in some instances.

As the market matures, maximizing the energy savings from LED

lighting systems will become increasingly dependent on maximizing

the successful installation of lighting controls that suit the use and

the user. Industry should continue to develop and refine educational

and certification programs aimed not only at selecting and design-

ing for control strategies but at ensuring that the specified lighting

control equipment suits both the use and the user and is correctly

installed and fully commissioned.

Manufacturer consortia should continue their efforts to develop

open-standard specifications and compliance testing programs that

allow lighting control products to be brought to market that offer

new features and deliver some level of interoperability. Energy-effi-

ciency organizations should consider focusing their lighting control

incentive programs on interoperable equipment.

Lesson 10: Lack of LED lighting product serviceability and inter-

changeability has created market adoption barriers in certain sectors.

Early experiences with some LED lighting products has shown that,

while the LED packages themselves may be long-lived, driver failure or

shifting color can cause what initially looked like a successful installa-

tion to fall short of client expectations. Modular luminaire designs may

allow for only the failed component to be replaced, reducing the risk of

unmet lifetime expectations and also entailing lower life-cycle costs.

Knowing that tomorrow’s products will perform better than

today’s can make it hard for lighting designers to decide when to start

specifying LED products. Luminaires designed with interchangeable

components, such as LED modules or light engines, allow users to

take advantage of evolving LED technology by, for example, easily

upgrading to deliver higher efficacy or the ability to control color

1403leds_39 39 3/3/14 4:31 PM

Page 42: LED Magazine - March 2014

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temperature when such features become

available. Industry should consider adopting

standardized modular interfaces and

developing products with serviceable or

interchangeable components.

Lesson 11: Existing lighting infrastructure

limits the full potential of SSL; more effort

is needed to open the doors to new lighting

systems and form factors.

Almost the entire SSL market remains

focused on products that fit into the exist-

ing infrastructure of legacy lighting prod-

ucts. While this is a necessary and expected

consequence of introducing a radically new

technology into a mature market, this cur-

rent focus sharply limits the potential of the

new technology.

Government organizations, codes and

standards bodies, and specifiers need to be

mindful that their lighting requirements

may restrict product form factors, function-

ality, and system operation. Careful develop-

ment of these requirements opens the door

to innovation and better product designs.

Energy-efficiency programs should con-

sider explicitly allowing for nonconventional

form factors and functionality and, where

possible, should move away from program

designs built around the concept of one-for-

one product substitutions.

Buyers are more likely to buy products not

compromised by the legacy infrastructure if

those products offer compelling functionality.

Manufacturers, lighting educators, the DOE,

and others could induce earlier customer

acceptance of lighting products by frequently

raising the issue of what SSL is capable of

when unconstrained by existing infrastruc-

ture. Manufacturers with innovative product

designs at the ready will be in the best posi-

tion to leverage this new opportunity.

Lesson 12: Programs that provide ways to

identify quality LED products have helped

support market adoption.

Verified test data and independent prod-

uct qualification are essential to help util-

ities, energy-efficiency programs, retail-

ers, and consumers evaluate LED lighting

products. But keeping pace with LED light-

ing technology is a challenge for qualifica-

tion programs that have minimum perfor-

mance requirements. Efficiency programs

should consider prioritizing the develop-

ment of custom options that help users iden-

tify quality LED lighting products. These

programs should target energy-efficiency

performance that will produce significant

energy savings if the technology is widely

adopted in the market.

Efficiency program requirements need

to keep pace with LED technology devel-

opment, balancing energy efficiency, light-

ing quality, and cost considerations. Testing

and documentation requirements should be

streamlined as much as possible, while still

maintaining confidence in qualified prod-

uct performance claims. Wherever possi-

ble, data should be shared across the vari-

ous performance verification programs, to

save time and expense for all participants.

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Page 43: LED Magazine - March 2014

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Page 45: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 43

focu

s o

n

Nîmes, France

The city of Nîmes and transportation authority Nîmes

Métropole won recognition for a project focused on the

urban community with a specific intent to accommodate

pedestrians in terms of lighting and passageways and also

novel lighting of the roadways that connect the city cen-

ter to the A54 motorway. We covered parts of the project

in an article last year (http://bit.ly/LImuCK). The project

included LED-based lighting of pedestrian tunnels and

walkways, and roadway lighting intended to guide traf-

fic in and out of the city. The city said the project “brought

human-scale comfort and safety” to the area while preserv-

ing the cultural value and aesthetics. Much of the project

was a new installation so figures on energy savings were

not available. But the average power of the LED luminaires

used was 56W whereas many of the legacy luminaires used

in the city were 150W. The panel appreciated the atten-

tion to aesthetics and the use of new types of fixtures that

truly leveraged the advantages of LEDs in form factor and

mounting options.

Ibarra, Ecuador

The city of Ibarra, Ecuador won for a lighting project

encompassing a major urban park — Parque Bulevar

Céntrica — located at the foot of the Imbabura Volcano.

The 240,000-m2 area serves residents and tourists alike

hosting cultural, entertainment, educational, and sports

activities. The project was an excellent example of the

combination of energy-efficient LED lighting with green

energy sources — in this case a new hydroelectric sup-

ply — to enable a major sustainable project. The project

delivered excellent lighting with 180 lx on sports areas and

75 lx on pedestrian and bicycle paths. Both figures were

far greater than requirements. Yet the city projects 43%

Sustainable LightingAt the Light Festival on December 7, 2013 in Lyon, France, lighting manufacturer Schréder

and the LUCI (Lighting Urban Community International) network of cities focused on

sustainable lighting announced the winners of the Auroralia 2013 Awards. This 5th

annual program jointly organized by LUCI and Schréder identified urban projects in

Nîmes, France; Ibarra, Ecuador; and Durham, England as first, second, and third prize

winners, respectively. Moreover, Heidelberg, Germany won special recognition. The awards

ceremony followed a judging session in November where jury members with vastly different

backgrounds argued the merits of different projects in terms of the energy-efficient LED or

other lighting involved, the applicability of controls and color capabilities, and the size and

breadth of the various projects. Here MAURY WRIGHT highlights the winners and other

impressive entrants.

Auroralia Awards

1403leds_43 43 3/3/14 4:31 PM

Page 46: LED Magazine - March 2014

44 MARCH 2014 LEDsmagazine.com

energy savings compared to if the park had been lit

with legacy sources. The jury panel was impressed

with the city’s determination to offer citizens and

visitors a better quality of life while caring for the

environment. Moreover, the development could lead

to increased tourism and economic development.

Durham, England

The Durham, England project was focused on the

UNESCO (United Nations Educational, Scientific and

Cultural Organization) World Heritage Site compris-

ing the Durham Castle and Cathedral. We covered

this project in far more detail in this issue (p. 26).

The project was especially interesting as it involved

an outdoor lighting system that had to do a brilliant job of light-

ing the iconic architecture while also protecting the local environ-

ment including preservation of the roosts of Pipistrelle bats. The

jury panel lauded the lighting design for using a DMX control sys-

tem and tunable lighting as it simultaneously limited the effects

to mostly white hues that maintained the historical aesthetics and

improved the visitor experience.

Heidelberg, Germany

Heidelberg, Germany nominated the redevelopment of an indus-

trial area into a mixed-use business, entertainment, and residen-

tial district that will include a comprehensive environmentally-

friendly footprint ranging from lighting to water use to power

generation. The Bahnstadt project will ultimately be larger than

the old city or Altstadt area and will include living space for a pop-

ulation of 5000 and 7000 jobs. The development will rely on pas-

sive house standards as a construction method and district-wide

heating supplied by renewable sources. The outdoor lighting sys-

tem will feature a comprehensive network for preventive mainte-

nance and adaptive control based on the Owlet system, and LED

luminaires in neutral and warm CCTs based on location. The jury

felt that the Heidelberg project could become a great blueprint for

new urban development and sustainable lighting, although the

development was still in the very early stages of build-out at the

time of the judging process.

Sabadell, Spain

Sabadell, Spain sought to install 7585 LED luminaires comprising

29% of the overall public city lighting as part of a program to meet

European Union guidelines on energy efficiency. The city broke

new ground by using

an ESCO (energy ser-

vices company) model

to finance the lighting.

ESCOs are fairly promi-

nent in North America,

but less so in Europe,

especially in major light-

ing projects. The ESCO

provided the upfront

investment, and will

recover the cost and pre-

sumably make a profit

over the 10-year term

of a maintenance con-

tract. The installation

also includes a network

that enables adaptive

control and automatic

meter-reading capabil-

ity for accurate deter-

m ination of power

usage. Sabadell projects

energy savings equal to

€1,040,000 ($1,431,000)

focus on

1403leds_44 44 3/3/14 4:31 PM

Page 48: LED Magazine - March 2014

46 MARCH 2014 LEDsmagazine.com

focus on

per year and that likely equates to a good deal for the

city and ESCO. Moreover, the city had sought to reduce

light pollution. And the new luminaires accomplish the

goal, eliminating uplight.

Los Angeles, California

The city of Los Angeles nominated a tunnel light-

ing project near Los Angeles International Airport on

Sepulveda Boulevard — running underneath the air-

port runways. Los Angeles was a third-place winner in

2012 for its broader LED streetlight program that is the

world’s largest (illuminationinfocus.com/news/3/12/6).

The 2013 project was perhaps the easiest of the 2013 entries to dis-

sect in terms of LED-based lighting technology and the advantages

afforded over legacy systems because the new installation replaced

an existing high-pressure sodium (HPS) installation. A total of

572 LED luminaires replaced 750 HPS fixtures. Moreover, the city

installed a network for control and automated maintenance. The

baseline energy savings of the project are 70% and that figure could

be increased through dimming the LED luminaires. The city also

projects 75% savings in maintenance costs. But perhaps the most

impressive result is the light quality. The city staggered brightness

by zone to help drivers adapt to lighting changes

with the time of day. Furthermore, the system

uses an asymmetrical beam distribution that

directs the lighting with the flow of traffic and

eliminates driver glare. For more information on

the challenges and benefits of LED tunnel light-

ing, see our recent feature (http://bit.ly/1h6yasK).

Mostar, Bosnia/Herzegovina

Effective LED-based lighting projects aren’t

just for major cities, as witnessed by the Mostar

project that covers the Old City area and the

Old Bridge, a zone protected as a UNESCO World Heritage Site.

Moreover, the city did an outstanding job of maintaining the his-

toric look, dismantling the legacy post-top lanterns with mercury

vapor sources and sending them to Minel‐Schréder for refurbish-

ment with Schréder’s LensoFlex 2 LED modules. The retrofit will

reduce the total energy required to power the lighting from 55 kW

to 10.6 kW. Savings are projected at 81% or 178,266 kWh per year.

The project is being realized in a way that has minimum impact

on residents and visitors and will ultimately result in far superior

lighting and a better outdoor experience to go with the sustain-

ability of the project.

Brussels, Belgium

Another lighting project of a UNESCO World Heritage Site was

the focus of the entry from Brussels, Belgium. The city’s Grand

Place has been relit in a dramatic fashion with a color-tunable sys-

tem that can present dynamic effects. We covered the first phases

of the project in late 2012 and featured it on our cover (http://

bit.ly/1m9Vw46). The city has now completed the installation of

façade lighting across all of the buildings surrounding the plaza.

Select areas use LED projectors to display historic images on

building walls. The Auroralia jury was fortunate to get a private

tour of the Grand Place project and see a dynamic night-time pro-

gram. Ironically, some of the jury questioned the justification for

the use of colored lighting in the project and the value it brought

to visitors. Others felt that the color programs could increase tour-

ism and boost the economy, more than covering the price premium

The Auroralia jury was composed of journalists that cover the

sustainable lighting space from a variety of angles ranging from enabling

technologies such as LEDs to urban planning. The panel included Maury

Wright of LEDs Magazine, Paul James of Mondo Arc , Britta Hölzemann

of Licht , Charlotte Fauve of Ecologik , Albert Punsola of Ciudad

Sostenible , Tom Rampelberghe of Light Partner , and Olivier Namias of

Lux. There were no firm rules that guided the judging process but rather

lengthy discussion interspersed with multiple rounds of balloting. The

panel considered 26 city projects from Los Angeles to Russia to India.

1403leds_46 46 3/3/14 4:32 PM

Page 50: LED Magazine - March 2014

48 MARCH 2014 LEDsmagazine.com

for the RGB fixtures. In any event, the LED lighting is 80% more

efficient than the former lighting in the plaza and reduced main-

tenance cost by a factor of four.

Jyväskylä, Finland

The Kuokkala Bridge had undergone a retrofit of the architectural

and façade lighting back in 2002, but until recently the roadway

was lit by globe-shaped luminaires housing HPS lamps. The city of

Jyväskylä and its citizens liked the globes that had become a rec-

ognizable element of the bridge’s architecture, but sought a more

energy-efficient lighting option. Indeed, the bridge was arguably

overlit with inefficient sources. The city ultimately replaced the

fixtures with luminaires from Ketonen Oy that integrate an LED

light engine from Valopaa Oy and new globes made by Elkamet.

The city determined that the bridge needed a light level of 1 cd/m2

and the installation delivers 1.5 cd/m2 using 3000K warm-white

sources. Even though cooler sources would have been more effi-

cient the city is still realizing 74% energy savings that will yield an

11-year payback. The bridge was part of a broader city plan called

Environmentally Friendly Outdoor Lighting that among other

things has seen streetlights upgraded and networked.

Entries span the globe

In addition to the Auroralia entries featured in our main article,

there were also entries from Lisbon, Portugal; Lyon, France;

Hamburg, Germany; Chennai, India; Cairo, Egypt; Bryansk,

Russia; Siófok, Hungary; Setúbal, Portugal; Rio de Janeiro,

Brazil; Passau, Germany; Pocking, Germany; Medellín, Colombia;

Málaga, Spain; and Marienhafe, Germany. The projects span

the range of small district lighting retrofits to city-wide projects.

Most of the projects were totally based on LED lighting, although

a few include a mix of LEDs and the latest-generation HID

products that are less efficient than LEDs but much improved

over prior generations.

Consider the Cairo entrant, lighting of the new Cairo Festival

City mixed-use development that will be home to 13,000

residents and 50,000 workers. The project utilizes 150W and

250W metal halide (MH) fixtures on main roadways and 53W

LED luminaires on residential streets. The designers used DALI

(digital addressable lighting interface) to connect the lights and

enable dimming during low traffic hours. The development also

includes a mix of LED and compact fluorescent (CFL) lighting

for landscapes and

building exteriors.

The Cairo entry had

perhaps the broadest

array of different

lighting applications

and fixture types in the

competition.

While there were a

few new developments

among the entries such

as Cairo, more typically

the projects were

retrofits. For example,

Siófok upgraded

roadway and park lighting with more than 2000 LED fixtures.

Traditional LED streetlights were the largest part of the project

but it also included decorative style lighting in the downtown

district. The retrofit project is delivering 555,324 kWh annual

energy savings.

Passau is another city that realized substantial savings with

the retrofit project nominated to Auroralia (shown here). The

project included an upgrade of almost 2500 fixtures with LED

lighting. Annual energy consumption went from 1,482,000 kWh

to 300,000 kWh. Pocking is a smaller German city that installed

781 luminaires taking energy consumption from 235,000 kWh

annually to 46,000 kWh.

Setúbal is another example of a project that used a mix of

LED and HID lighting. The city used high-pressure sodium (HPS)

to light some of the arterial roadways. But the downtown area

is lit with LEDs and the city says that the project has resulted in

its citizens making greater use of parks and walkways after dark.

The new lighting maintains a historic look, and the city is saving

266,727 kWh annually. Indeed, the Auroralia Awards drew many

noteworthy projects that both boost quality of life for residents

and help trim global energy use and carbon emissions.

1403leds_48 48 3/3/14 4:32 PM

Page 51: LED Magazine - March 2014

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Békéscsaba, Hungary

Békéscsaba nominated a downtown modernization project centered

around Szent István square for the Auroralia Awards. The project

included both new installation and retrofit of post-top and suspended

acorn-style luminaires with Nagy-Kecskemet, Panon2, Terra Midi, and

Terra Maxi LED fixtures from Schréder. We will get to the energy sav-

ings in a minute, but the city has received significant response from

the public about the project. The city said 90% of the public reaction

has been positive and that the residents have an increased apprecia-

tion for the importance of streetlighting. Moreover, the city said the

broad-spectrum white light makes the buildings

and monuments appear in their natural color and

beauty, whereas the prior lighting had made them

appear to have a yellow coat. The new lighting uses

6924 kWh less energy than the old lighting.

Tartu, Estonia

The city of Tartu has undertaken the first phase

of a streetlight retrofit replacing around 500 leg-

acy fixtures with LED luminaires. Even with

the first phase the city decided to install adap-

tive controls that will adjust light levels based

on the traffic present at different times of the

night. The city projects energy and maintenance

cost savings of €35,000 ($48,000). In its Auroralia

application, the city specifically noted that the

new lights would improve the quality of life for

1403leds_49 49 3/3/14 4:32 PM

Page 52: LED Magazine - March 2014

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residents and visitors. Indeed, the nearby photo depicts excellent

uniformity. And remember that the level can be reduced. The city

also said that the new fixtures minimize light pollution.

Oldenburg in Holstein, Germany

The City of Oldenburg relies on tourism and foresaw LED lighting as

a way to show residents and visitors that it was a forward-looking

city with an environmental outlook. The city was concerned about

carbon emissions and the impact of lighting on wildlife including the

local bat population. By the end of 2013, the city had retrofitted all but

700 municipal fixtures to LEDs. The project has delivered 87% energy

savings and reduced carbon by 184 tons. The city hopes to retrofit the

remainder of its lighting this year. Payback for the entire project is

expected to be five years, and the lights are rated for 35 years of life.

The LED lighting is delivering light levels 20% higher than required.

focus on

1403leds_50 50 3/3/14 4:32 PM

Page 53: LED Magazine - March 2014

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Page 54: LED Magazine - March 2014

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Page 55: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 53

optics | SSL DIFFUSERS

When the use of tertiary optics or

diffusers is an after-thought in

the design of lamps and fixtures,

the designer ends up facing many integration

and performance issues after project comple-

tion. Conversely, tertiary optics can deliver

many benefits in LED-based lamp and lumi-

naire design when conceived at the start of the

product development. Let’s discuss the con-

cept of “collimate then diffuse” for solid-state

lighting products and review real-world exam-

ples. We will consider various formats of ter-

tiary optics like film, rigid panels, and injec-

tion-molded parts along with a discussion on

how high- and low-performance optics differ.

LEDs have introduced a greater level

of complexity to fixture and lamp design.

Lighting designers have had to learn new

techniques to control the light from these

new light sources, as well as new terminol-

ogy associated with these techniques. While

the radiation from a bare LED with a pri-

mary optic can be fairly wide (80–90°), it is

considered to be directional when compared

to a conventional source like an incandes-

cent filament. In projection applications

where the target plane of illumination is

more than 0.5m distant, the directional

nature of an LED is not alone sufficient for

most lighting uses. Indeed, a secondary optic

such as a total internal reflection (TIR) lens

or ref lector is required to collimate the

beam to somewhere between 3.5–15°. A ter-

tiary optic such as a diffuser can also be

required to improve the color and/or spa-

tial uniformity as well as shape the beam to

suit the photometric requirements.

Tertiary optic

examples

One example of a

real-world product that

has all of these optical com-

ponents is GE’s LED PAR38

lamp (Fig. 1). The LEDs with

the primary optic are

positioned at the base

of the lamp; a reflec-

tor surrounds the

LEDs with a circu-

lar Fresnel lens posi-

tioned at the output

aperture. Both the reflec-

tor and Fresnel lens are considered to be sec-

ondary optics. A diffuser is placed on top of

the Fresnel lens to clean up non-uniformity

caused by the Fresnel structure and adjust

the beam to medium and flood angles.

Another example is an LED recessed

downlight (Fig. 2). Here the secondary

optic is the reflector that colli-

mates the radiation from the

LEDs and the tertiary optic

is a diffuser that increases

the beam angle as well

performing a hiding

function that pre-

vents someone from

seeing the LEDs

under direct view-

ing conditions.

In the M R16 -

lamp sector, Soraa

relies on yet a differ-

ent structure. Here

the secondary optic is

a TIR-based collima-

tor. The tertiary optic

is an interchangeable

accessory that is eas-

ily replaced by the

customer in the field.

The accessory kit also

includes a linear spread

optic that provides for lin-

ear or elliptical illumination

patterns at the target plane.

The easy and f lexible use of

tertiary optics of different

kinds was what the designers

of the product had in mind from

the outset. As a result, the design of

the secondary optics and the heat sink

were optimized for use with tertiary optics.

One last example is an LED architectural

lighting fixture (Fig. 3). Here the secondary

optic is again a TIR- or parabolic-reflector-

based collimator. The tertiary optic is an

interchangeable accessory that is installed

in the field and serves two functions: to

mix the red, green, and blue com-

ponents of the illumination in air

before hitting the target plane,

and to shape the beam

pattern. Architectural

lighting installations are

typically complex for two

main reasons. First,

the distance of the

fixture from the

Tertiary optics deliver benefits

in SSL product design

LEDs are relatively directional light sources but require secondary and tertiary optics to meet the

needs of lighting designers and specifiers. SULEYMAN TURGUT explains how tertiary optics are often a

necessity for proper lamp and luminaire performance and can be cost-justified in new SSL products.

SULEYMAN TURGUT is director of sales,

Luminit LLC.

FIG. 1. A GE Lighting PAR38

lamp with a tertiary optic.

FIG. 2. A

typical LED-

based recessed

downlight.

1403leds_53 53 3/3/14 4:32 PM

Page 56: LED Magazine - March 2014

54 LEDsmagazine.com

optics | SSL DIFFUSERS

illumination or target plane can be differ-

ent for each project, and the target or object

of illumination is always different in size and

orientation (e.g., horizontal or vertical). Sec-

ond, a variety of diffusion angles (symmet-

rical and asymmetrical) can be offered as

options to help customize the fixtures to

accommodate many of these variables in a

lighting project.

Collimate then diffuse benefits

These four examples help illustrate the con-

cept of collimate then diffuse that many LED

lighting designers use in specification proj-

ects. There are four main benefits of using

this design concept:

Single secondary optical design: If a

diffuser is designed into the product from the

beginning, there is no need to redesign the sec-

ondary optics for a different project or installa-

tion that requires a different beam angle.

Reduced total cost: When only one

reflector or TIR secondary optic is required,

there is only one mold to be manufactured,

instead of multiple. Due to a single stock-

keeping unit (SKU), the inventory costs are

also reduced.

Flexibility: The same fixture can be used

in multiple projects since the beam angle

change is a simple as changing out a win-

dow. For instance, due to the long throw in

architectural lighting applica-

tions these fixtures require very narrow

beam angles (e.g., 1–3.5°) and the illumina-

tion target is usually larger than the spot size

of the fixture and varies with each project.

The diffuser accessory provides the flexibil-

ity for the same fixture to be used in multiple

installations by allowing for multiple beam

angles in the same fixture (Fig. 4).

Cleaner target plane: Regardless of how

well designed the secondary optic is, there

will be always be some level of non-unifor-

mity in the intensity or color at the target

plane. In spot lamp applications with nar-

row beam angles, a small-angle tertiary

optic or diffuser (e.g., 2° or 3.5°) works well

to maintain the punch while removing stria-

tions in the illumination plane (Fig. 5).

Materials, formats, and options

Now let’s discuss the material and manufac-

turing aspects of tertiary optics. Materials

for tertiary optics are available in both thin

film around 0.25 mm and thick sheet options

around 3 mm (Fig. 6). Rolls of thin film up to

600 mm in width are common, but for linear

fixtures (e.g., wall grazers and washers) the

mini-roll format allows for easier assembly

and integration. For small fixtures or lamps

less than 150 mm in size (e.g., recessed

downlight, PAR lamps, etc.), where the vol-

umes are higher and selling prices lower, the

injection-molded format using thicker mate-

rial is the best option. Molding allows for the

diffuser to double as the window of the fix-

ture or lamp and the tertiary optic.

Polycarbonate is the preferred plas-

tic of choice for lighting applica-

tions. It’s available in UV-stable

versions for outdoor applica-

tions and in UL-listed versions

to meet flammability require-

ments that are typically dictated

by the class of the LED driver.

Holographic versus

volumetric diffusion

There are also different approaches

to tertiary optics that must meet

application requirements. Tertiary

optics are available in low- and

high-performance versions.

The main difference lies in

the diffusion mechanism. High-performance

holographic diffusers incorporate a sub-

micron surface relief pattern on top of a very

clear substrate. Through a combination of dif-

fraction and refraction, the diffusion (which

occurs only on the surface of the substrate) is

extremely efficient (up to 92%) — independent

of thickness — and provides precise angular

beam control.

Lower-performance diffusers, such as

volumetric diffusers, incorporate scat-

tering elements within the volume of the

substrate. These diffusers typically are

less efficient in the 30–70% transmission

range. The optical properties of volumet-

ric diffusers are very dependent on thick-

ness and provide little or no control of the

beam angle of a lamp or fixture.

FIG. 3. An Elation Lighting

architectural wall washer.

FIG. 4. The same fixture with different

tertiary optics delivers vastly different

lighting effects (images courtesy of City

Theatrical).

1403leds_54 54 3/3/14 4:32 PM

Page 57: LED Magazine - March 2014

Philips Fortimo LED Line Gen 2

Systems

Features and Benefits

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1403leds_55 55 3/3/14 4:32 PM

Page 58: LED Magazine - March 2014

optics | SSL DIFFUSERS

FIG. 5. A diffuser producing the spot beam on the right eliminates the striations

evident in the beam on the left.

FIG. 6. Tertiary optic materials on the left and finished products on the right.

Optical modeling

One of the most valuable tools used by opti-

cal engineers and designers in the product

development phase is optical and lighting

simulation software. It’s been difficult to

model the behavior of tertiary optics in the

past. Today packages like LightTools from

Synopsys, TracePro from Lambda Research,

various tools from Optis, and Zemax from

Radiant Zemax are now compatible with

BTDF (Bi-directional Transmittance

Distribution Function) data. This data

describes how a ray of light behaves after

entering and exiting a diffuser. This data

has been collected for a variety of off-axis

incident angles; thus it is useful in simulat-

ing wide-angle sources like LEDs.

In conclusion, to avoid issues in fixture

and lamp performance after project com-

pletion we recommend considering the use

of tertiary optics in new fixture and lamp

designs. The main benefits include single

secondary optical design, reduced total cost,

flexibility, and a cleaner target plane.

1403leds_56 56 3/3/14 4:32 PM

Page 59: LED Magazine - March 2014

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Page 60: LED Magazine - March 2014

Subscribe Today!TECHNOLOGY AND APPLICATION OF

LIGHT EMITTING DIODES

SUBSCRIBE TODAY! Log on to www.ledsmagazine.com/subscribe

LEDs Magazine is the market-leading resource for

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1403leds_58 58 3/3/14 4:32 PM

Page 61: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 59

UV-LED exposurecauses chemical reaction

Liquids applied:inks, coatings,

adhesives

Liquids harden,fnal product is UV cured

o

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m

p

p

m

op

o

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op

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Photo-initiator

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science | UV CURING

When people hear the terms “light-

emitting diodes” or “LEDs,” most

people think of visible LEDs for

lighting applications. Indeed, LED tech-

nology is used increasingly throughout the

world for indoor lighting, outdoor lighting,

street lighting, automotive, and signage.

But there are many other industrial appli-

cations such as curing (drying) and counter-

feit detection. Ultraviolet (UV) LED technol-

ogy for curing is one of the market segments

that has gained worldwide acceptance and

continues to grow. Let’s examine the state

of UV curing technology and consider how

well LEDs are fulfilling promises of taking

over that space.

UV-LED curing refers to a technique that

utilizes energy output from the LEDs in the

UV spectrum to treat inks, coatings, adhe-

sives, and other UV-curable materials. The

energy generated by the UV light triggers a

chain reaction resulting in polymerization

of the material, thus hardening or curing the

material (Fig. 1). For more background on

UV-LED curing, see “UV LEDs ramp up the

quiet side of the LED market” (links on p. 63).

Traditionally, mercury-based UV lamps

have been utilized for curing, but now more

energy-eff icient and environmentally-

friendly LED-based UV technology has

proven a superior solution for many applica-

tions. LED curing technology uses semicon-

ductor-based LEDs to project the UV light

when an electric current is passed through

them. When an LED is forward-biased,

electrons are able to recombine with elec-

tron holes within the device, thus releasing

energy in the form of photons.

The color of the light emitted or corre-

sponding energy of the photon is determined

by the energy gap of the semiconductor mate-

rial. A number of companies that make LEDs

used for general illumination also make LEDs

that radiate in the UV spectrum.

Advancements in UV-LED curing

It is an accepted fact for many industries

that LED lamps provide many advantages

including lower energy consumption, lon-

ger lifetime, improved robustness, smaller

form factor, and faster on/off switching.

Those advantages are also important in cur-

ing applications.

UV-LED curing technology has advanced

significantly in the past few years and is now

readily available for a variety of applications

in printing, coatings, and adhesives. There

are many benefits driving companies to

move toward acceptance of UV-LED technol-

ogy such as higher productivity and a more

environmentally-friendly solution, which

more and more end customers are demand-

ing. As manufacturers are developing UV-

LED curing systems, knowing how the key

sub-components work together will help in

creating the optimum system and thereby

reducing the overall environmental impact

of the process and at the same time main-

taining or improving productivity and prod-

uct performance.

Application segments

Curing is a broad market with many appli-

cation niches. But let’s consider some of the

major application segments:

Printing: The UV curing process has been

UV-LED advancements extend

the promise in curing

The year 2013 witnessed an expansion of LED usage in UV curing applications with higher-power

emitters enabling faster cure times across a variety of life science and industrial applications, writes

BILL CORTELYOU, and component lifetimes have increased as well.

BILL CORTELYOU is president and CEO of

Phoseon Technology.

FIG. 1. UV light instigates a chain reaction resulting in curing of materials such as

inks or adhesives.

1403leds_59 59 3/3/14 4:32 PM

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60 MARCH 2014 LEDsmagazine.com

355 365

LED only

385 395 405 415

Wavelength (nm)

Relativeintensity

Relativeintensity

Wavelength (nm)

LEDrange

LED 385/395/405 nm

LED 365 nm

Mercury lamp

UVC

100-280 nm

UVB

280-315 nm

UVA

315-400 nm

Visible light

400-700 nm

Infrared

700-1800 nm

science | UV CURING

in use in the printing industry for more than

thirty years. LED curing technology for UV

printers is rapidly replacing older technol-

ogy with compelling advantages of better

economics, system capabilities, and envi-

ronmental benefits. UV-LED curing technol-

ogy is ideal for the UV curing of inks in dig-

ital inkjet, screen, f lexographic, and other

printing processes.

Coatings: A significant number of coat-

ings are cured worldwide today with UV-

LED sources in applications ranging from

traditional materials such as f looring and

cabinetry to advanced electronics. Material

development and long-term performance

testing will further open markets in the

areas of automotive, electronics, residential,

and commercial construction materials.

Adhesives: UV adhesives are a great tool

in modern assembly and manufacturing

processes with UV-LED electronic control

and stability, ensuring excellent results in

a wide variety of UV-LED adhesive appli-

cations from medical devices to the most

advanced consumer electronics.

Snapshot of 2013

2013 was another year of strong growth

in UV-LED adoption. In the last few years,

there has been much discussion around the

rate of adoption and usefulness for the wide

range of UV curing applications. Essentially,

the question has been “Will UV-LED cur-

ing technology fulfill its promise?” Well,

the answer is yes! In fact, it has exceeded

the promise and will continue its strong

growth, accelerate, and open new UV cur-

ing markets.

The early concerns of output, lifetime, and

cost have all been met with rapid technol-

ogy and product improvement. Today, UV-

LED curing technology meets a wide range

of application requirements and is continu-

ing to improve at a rapid pace. Lamps of 16

W/cm2, which cure at the highest of speed

requirements, have been shipping in volume

for more than two years. Lamp manufactur-

ers routinely quote lifetime expectations in

excess of 20,000 hours of on-time — double

what was quoted a few years ago. Soon, lead-

ing manufacturers will be producing lamps

promising even longer lifetimes — likely

around 30,000 hours, matching or exceed-

ing the life of various curing installations.

Nearly all UV-curable materials providers

have UV-LED-curable chemistries along with

aggressive technology and product roadmaps.

Although the monochromatic nature of

UV-LED lamps requires special consideration

from the chemists, it has not been a long-term

impediment as once thought.

One of the most exciting aspects of utiliz-

ing a UV-LED curing process is that it opens

many new process possibilities with its

precise electronic control of energy

delivery. Many users have tai-

lored their processes to achieve

results unattainable through

other means. Today there

are many proprietary

uses of energy con-

trol across varying

applications.

Recent milestones

Consider the milestones reached

in 2013. The Labelexpo Europe

2013 tradeshow reflected large-

scale UV-LED adoption. The

event validated the claims of rapid

adoption of UV-LED curing. The

show reported record-breaking attendance

figures by attracting 31,795 visitors (up 11%

over 2011) from 158 countries (up from 123

in 2011) with nearly 600 exhibitors (up from

550 in 2011). Everywhere they looked, attend-

ees saw UV-LED curing systems being imple-

mented on machines. To UV LEDs’ tradi-

tional strength of digital inkjet were added

rotary screen printing, area curing, offset,

and flexographic printing.

Comparing Labelexpo 2013 to Labelexpo

2011 proves just how rapidly the industry has

adopted the technology. More than 80 UV-

LED curing lamps were installed on equip-

ment at the 2013 show, up from 10 instances

during the 2011 show for an 8x increase. Cur-

ing uses ranged from pinning to full cure

and many of the printers were 100% UV-

LED based.

Attracting the highest ever number of

entrants in its history, the Label Industry

Global Award for Innovation,

sponsored by Label &

Narrow Web, Labels

& Labeling, and Nar-

roWebTech maga-

zines, was jointly won

by Mark Andy and Flint

Group Narrow Web. Flint

Group was honored for its

Ekocure UV-LED ink technol-

ogy, which the judges described as

providing improved cure response,

cost and productivity savings, waste

reduction, energy savings, and

enhanced safety that will undoubt-

edly have a significant impact on

the future of the label industry.

Mark Andy was recognized for its

complementary ProLED ink curing technol-

ogy, which delivers high production rates and

50% energy savings.

More material formulation suppliers

At the advent of UV-LED curing, some ten

years ago, very few types of inks, coatings,

and adhesives were compatible with UV-LED

technology. As Fig. 2 shows, the spectral

energy distribution of UV LEDs is quite

different from that of mercury lamps and

indeed is in a much narrower band. That dif-

ference required new material formulations.

FIG. 2. The spectral energy distribution of UV LEDs is different from that of legacy

mercury lamps that were broadly used in the past.

FIG. 3. An air-

cooled UV-LED

curing system.

1403leds_60 60 3/3/14 4:32 PM

Page 63: LED Magazine - March 2014

science | UV CURING

Today, large numbers

of material vendors tout

their support for LED for-

mulations. New resins,

monomers, oligomers,

and photo-initiators are

being developed, expand-

ing new possibilities in

UV-LED cured materi-

als. Not only inks but also

coatings and adhesives are

now widely available that are either spe-

cially formulated for LED or work with both

LED and traditional sources.

Increasing performance

UV-LED lamp technology has advanced to

a point where it now offers enough power

and capability to support a very wide range

of existing and new industrial applica-

tions. With compatible material formula-

tion, UV-LED energy output is now equiv-

alent or better than traditional UV curing

lamps. UV-LED curing units have become

more efficient in delivering higher

energy to the media, thus driving

not only increased throughput and

process f lexibility but also envi-

ronmentally-friendly and energy-efficient

solutions. End users are rapidly moving to

UV-LED curing technology due to the accu-

mulation of benefits. Figs. 3 and 4 show air-

and water-cooled UV curing products.

The advancements are opening new

applications. Due to recent advances in

high-powered air-cooled products, UV-LED

curing technology now enables the wood

coatings industry to leverage the technology

for applications such as edge

coating, roller coating, and

digital printing. UV-LED

technology drastically

reduces energy con-

sumption and sig-

nif icantly reduces

work-piece surface

temperature. Edge coat-

ing lines utilize UV LEDs to

ensure consistent, high-quality

results. Machines can be made

more compact due to small form

factor; speed can be increased

due to consistent UV output; and the dif-

fuse nature of UV-LED light can be used to

more effectively cure shaped surfaces that

previously required multiple lamps at var-

ious angles.

UV LED is a perfect match for roller coat-

ing lines, both for controlled gelling and

full-cure stations. The benefits include bet-

ter factory floor utilization due to shorter,

more efficient lines; increased uptime with

FIG. 4. A water-

cooled UV-LED

curing system.

1403leds_61 61 3/3/14 4:32 PM

Page 64: LED Magazine - March 2014

62 MARCH 2014 LEDsmagazine.com

science | UV CURING

no degradation in UV output; lower-cost

input stock due to lack of infrared heat; and

reduced operating costs by more efficient

electricity use and no need for costly air-

ducting systems.

While technically not a wood application,

creating a natural wood-grain look on diverse

materials is made possible with UV-LED

cured ink-jet printing. By using a combina-

tion of pinning and full-cure lamps, a realistic

look — and more important, feel — is enabled

by creating texture to mimic the grains of

natural wood. This is especially valuable in

decorative and accent applications.

New applications enabled by UV LEDs

There are many new applications being

enabled by UV-LED technology. Consider

advanced f lat-panel display manufactur-

ing for cell phones, OLED TVs, and touch

screens (Fig. 5). UV-LED technology is a

great fit and offers more consistency with

less heat transmitted to the panel. By elim-

inating heat damage of electronic compo-

nents, LED technology can be used on more

materials to improve manufacturing yields.

UV-LED curing technology is also being

utilized for decorative bottle printing for

glass containers for spirits, health and beauty,

wine, cider, beer, bottled water, soft drinks,

food, and the promotional glassware indus-

try. This decorating process utilizes UV-LED

light sources for curing inks on glass contain-

ers to improve the quality of print.

Printing braille with UV LED allows for

rapid personalization and f lexibility for

labels and packaging. If you want to change

the message frequently (e.g., change the

date, name, language, etc.), all you need to

do is update the computer running the line.

If you use a traditional stamping method

instead of printing, you will need a new

pair of wheels for each change. In addition

to personalization and flexibility, the print-

ing line allows for higher-quality printed

braille on the packaging. This makes the

labels easier to read with increased language

differentiators.

The applications extend to decorative

uses. Decorative printing processes allow

for ultrahigh gloss, matte, and holographic

effects. Cast and cure is a fast-growing

technology that creates a holographic-style

decorative finish on a variety of substrates

FIG. 5. Flat-panel display manufacturing is one of several applications enabled by

UV-LED sources.

1403leds_62 62 3/3/14 4:32 PM

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LEDsmagazine.com MARCH 2014 63

L E D D R I V E R S

5 - Y E A R W A R R A N T Y

1 0 - 3 0 0 W A T T M O D E L S

4 8 0 V I N P U T

C U S T O M D E S I G N &

M O D I F I C A T I O N S

D I M M I N G O P T I O N S

U S E N G I N E E R I N G

S U P P O R T

E X T E N S I V E

D I S T R I B U T I O N

S U P P O R T

A U T E C . C O M

8 0 5 . 5 2 2 . 0 8 8 8

D C I N P U T

science | UV CURING

for sheet-fed and web applications. Cold foil

is the application of metallic foil, in line, at

press speed in an infinite spectrum of colors.

These effects can be created with UV-LED

technology in a wide variety of environments.

The low-temperature benefits of UV LEDs

also extend the usage range in terms of sub-

strates. Due to the low heat generation, UV

LEDs support curing on surfaces such as

wood, metals, ceramic tiles, plastics, glass,

and plastic for 3D textured printing. Pinning

of successive layers allows textures that pro-

vide for depth and realism. Additionally, cur-

ing of adhesive or coating in successive layers

provides for better adhesion and flow control.

Projecting UV-LED curing

2014 will see a continued rapid increase in

UV-LED adoption along with a number of

new UV-LED applications where traditional

curing solutions are not practical. Advanced

display technology such as flexible, high-res-

olution organic LED (OLED) and high-speed

and dimensionally-precise additive manu-

facturing will both benefit from the precise

energy delivery and low heat-load capabil-

ity of the UV-LED systems. Undoubtedly,

additional applications will emerge as the

UV-LED ecosystem advances. Materials

formulators will have an expanded choice

of their key constituents including mono-

mers, oligomers, resins, and photo-initia-

tors exclusively developed for LED’s charac-

teristic UV output.

Regulator issues will also drive the tech-

nology forward. Legislative and non-govern-

mental organizations worldwide continue to

address concerns around products contain-

ing mercury. The European Union’s “Reduc-

tion of Hazardous Substances” (RoHS II)

places emphasis on finding suitable alterna-

tives to mercury-containing devices while

the United Nations' UNEP program targets

the removal of mercury. UV-LED lamps today

offer cost-effective and capable solutions for

the majority of curing requirements.

2014 will see a continued rapid increase in

UV-LED adoption along with a number of new

UV-LED applications where traditional curing

solutions are not practical.

LINKS

UV LEDs ramp up the quiet side of the LED market

Relative to visible LEDs, UV LEDs are a quiet market at only $30 million, yet recent breakthroughs

in radiant power and intensity have enabled the displacement of mercury-vapor lamps in applica-

tions including UV curing and counterfeit detection.

http://bit.ly/1bY7FTg

SETi and the USDA document UV LEDs extending shelf life of fresh produce

Sensor Electronic Technology Inc reports that LEDs in the UVB spectral band can double the shelf

life of refrigerated produce after a study based on strawberries that was conducted with the US

Department of Agriculture.

http://bit.ly/MESw3d

LUXeXceL demonstrates its patented manufacturing technology for printable optics

A new methodology to design and manufacture optics for LED lighting was presented at the Bre-

genz, Austria LED professional Symposium and explained in detail in various workshops.

http://bit.ly/1eYOngo

LED Engin announces UV LED for demanding curing applications

LED Engin has announced the Gen 2 family of ultraviolet (UV) LEDs that radiate in the 365-nm

band and that target curing applications for industrial, life science, and other uses. The company

asserts that the LEDs deliver four times the power density of competing UV LEDs.

http://bit.ly/1nR35eJ

1403leds_63 63 3/3/14 4:32 PM

Page 66: LED Magazine - March 2014

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Page 67: LED Magazine - March 2014

LEDsmagazine.com MARCH 2014 65

Companies are striving to design

innovative and reliable solid-state

lighting (SSL) products while reduc-

ing the cost of product development and

time to market. At the same time, the pace

of LED-based product innovation has

increased dramatically and is a primary con-

tributor to lighting companies’ overall prof-

its and market share. The challenges in this

environment include increasing product

complexity and the time and cost required

to create physical prototypes. The challenge

is especially acute in that SSL development

is a multidisciplinary undertaking requiring

optical, electronics, mechanical, and ther-

mal skills. Thermal design is especially

important in terms of SSL product reliabil-

ity, and simulation can be critical in devel-

oping a good thermal-management scheme

in a timely manner. A recent luminaire

development by BUCK d.o.o. illustrates the

advantages afforded by simulation.

Simulation tools can help lighting manu-

facturers meet tight market windows even

with constrained engineering resources. Such

tools allow the development team to perform

more and more sophisticated analyses earlier

in the development process. Successful prod-

ucts today must be more ergonomic and envi-

ronmentally efficient. Developing such prod-

ucts, especially in a way that the products can

meet customers’ desired price points, requires

the design team to evaluate more approaches

to elements such as thermal than could rea-

sonably be considered if prototypes of each

approach had to be constructed.

Outdoor luminaire design

BUCK is a company in Belgrade that pro-

duces luminaires for architectural and med-

ical illumination. The company has expanded

its work to outdoor luminaires, and they took

on a joint project with Panasonic Serbia to

create a self-cleanable heat sink for outdoor

lighting fixtures that would improve on an

existing extruded heat sink. Thermal design

is critical in SSL products because high tem-

peratures can reduce an LED’s light output

and cause color shift —

effectively shortening the

component’s useful effec-

tive life. Indeed, heat dissi-

pation design is a key fac-

tor in the performance of

high-power LEDs.

The thermal manage-

ment of a street luminaire

is particularly challenging

because the ambient tem-

perature changes depend-

ing on season and location.

Finding the optimum solu-

tion for thermal problems

can take 80% of the time the development

team spends on designing a new product.

During the design development phase of

the street light fixture, the R&D team started

with the question, “How can we solve the cool-

ing of LED modules in the most efficient way?”

Based on years of experience in designing heat

transfer equipment, the answer was easy: Take

the heat away from the LED module, provide

enough surface-to-heat dissipation, and pro-

vide good airflow.

But some questions weren’t so easy:

• How much airflow is needed to take the

heat away at 55°C ambient temperature

from the 140W high-power LED module?

• In what way can we provide the opti-

mum heat dissipation surface?

• Where will the hottest air pockets be

formed?

Optimizing the heat-sink design empiri-

cally would require a lot of time and money.

The R&D team decided to use software simu-

lation and analyses to speed up the develop-

ment time. The computational fluid dynam-

ics (CFD) software they chose, FloEFD from

Mentor Graphics, provides guidance and

help so that engineers who are not CFD spe-

cialists can perform fluid flow, cooling, and

other analyses as part of their design process

and within their product design tool.

CFD simulation

The software allows engineers to perform

CFD automatically — without the atten-

tion of a trained specialist. This automa-

tion means that product designers can try

out a succession of ideas on a design with-

out risking the project deadline, while also

reducing simulation time compared to tra-

ditional CFD tools.

The CFD software also makes it relatively

easy to conduct what-if tests. FloEFD helps

create multiple variations of designs by

Simulation enables optimum LED

street light heat-sink design

DJORDJE ZIVANOVIC and RICHARD OZAKI describe a thermal-design methodology that enabled the

development of a new self-cleaning heat sink for an outdoor LED luminaire using simulation tools.

DJORDJE ZIVANOVIC is an industrial

designer at BUCK d.o.o. RICHARD OZAKI is

a senior application engineer for European

customers in the mechanical analysis division

of Mentor Graphics Corporation.

design forum | THERMAL SIMULATION

FIG. 1. Thermal simulation of the original heat-sink design,

showing airflow in FloEFD.

1403leds_65 65 3/3/14 4:32 PM

Page 68: LED Magazine - March 2014

66 MARCH 2014 LEDsmagazine.com

design forum | THERMAL SIMULATION

modifying parametric CAD configurations,

which can then be analyzed without hav-

ing to reapply loads, boundary conditions,

material properties, and the like. The engi-

neer simply compares the results among the

many design options to choose the best pos-

sible design.

The simulation software enables product

designers as well as specialists to acceler-

ate key decisions at their workstations as

they experiment with design scenarios

and as they hone in on the best, most effi-

cient, reliable, and cost-effective design.

This intuitive virtual prototyping process

allows designers to optimize a product dur-

ing the design stages, with that first phys-

ical prototype often being the design that

goes into final manufacturing, delivering

the best design at lower cost, and getting it

to market faster than ever before.

Without simulations, the R&D team

would have needed at least 6 to 10 physi-

cal prototypes, and the team still wouldn’t

have been able to guarantee they had the

best solution. Empirical testing would have

cost a minimum of three additional months

of development time and at least €500 in

prototype costs. By using FloEFD, they cut

thermal simulation and management time

down to one month.

Solid modeling

The team performed the series of simula-

tions in FloEFD based on a parameterized

CAD model created in CATIA V5, a solid

modeling tool. FloEFD V5 is a concurrent

CFD product, and that allows the model

to be immediately available for analysis

preparation within the CATIA environ-

ment. Engineers use a configuration wiz-

ard to prepare the solid model by applying

loads and boundary conditions and finally

meshing the model before

analyzing it. By design-

ing the heat-sink model

in CATIA as a mechani-

cal model and simulat-

ing with FloEFD from the

thermal standpoint, the

thermal properties can be

attached to all the poten-

tial shapes considered for

the heat sink, and the LED

module that is the source

of heat.

After the design optimi-

zation of the heat sink, the

team obtained data on the

number, height, and thick-

ness of the fins that would provide the best

possible heat dissipation for the LED mod-

ules (Fig. 1). As part of the optimization pro-

cess, the team also wanted to test the effect

on cooling of dust accumulation over the top

of the heat sink.

Dust/dirt deposition reduces the avail-

able surface area for heat

transfer, creates addi-

tional thermal resis-

tance for heat to get to

the ambient, and reduces

the amount of airflow that

can travel between the

heat-sink fins removing

heat. In the simulation,

the team added a com-

ponent to represent dirt/

dust placed over the top of

the heat sink (Fig. 2).

Self-cleaning design

In addition to optimum

cooling, the goal of the team included

designing a self-cleaning heat sink. The

desired self-cleaning effect requires high

air velocities relative to natural passive con-

vection standards, in order to minimize dirt

deposition. The airflow was simulated using

the FloEFD particle study feature. The par-

ticle study feature in the simulation soft-

ware permits injection of virtual particles

with a material diameter and mass into the

fluid flow to determine where particles will

accumulate and erode surfaces. This lets

the engineers visualize where dirt will fall

out of the flow and gather on the heat sink,

or preferably be carried out of the heat sink.

The use of thermal simulation software

both significantly shortened the develop-

ment time of the SSL product and provided

operational details that would have been

difficult to obtain otherwise. The result

for BUCK was the design of a new heat-sink

model with vertical fins, which features a

higher airf low for the self-cleaning effect

that prevents dirt deposition (Fig. 3).

The self-cleaning heat sink has a simi-

lar mass to the original one, but it doesn’t

need as much additional work and time on

the milling machine. The simpler manufac-

turing process resulted in not only cost sav-

ings but also significantly reduced main-

tenance in the end product, and achieved

longer product life.

Modeling the LEDs

The team also utilized a new FloEFD LED

module feature that delivered reliable results

effortlessly. The values from the FloEFD simu-

lations were within 3% of the results obtained

later by measurements on the physical model.

The LED module in FloEFD simulates

an LED component as a compact package

based on either a simple two-resistor model

or an advanced measurement-derived

model. The detailed model includes a

unique solution to the challenge of design-

ing SSL and allows thermal and photomet-

ric models of LEDs obtained from testers to

be used in FloEFD under constant-current

operating conditions.

The model correctly accounts for power

FIG. 3. Thermal simulation of the new heat-sink design with

dirt deposition.

FIG. 2. With optimization in the thermal simulation

software, the team was able to verify quickly and reliably

whether the dirt deposition on the heat sink could lead to

malfunction while the luminaire is working.

1403leds_66 66 3/3/14 4:32 PM

Page 69: LED Magazine - March 2014

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LEDsmagazine.com MARCH 2014 67

design forum | THERMAL SIMULATION

that is emitted as light when calculating the

heat dissipation in the LED, with the tem-

perature, power consumption, and light

output (hot lumens) predicted by the soft-

ware. A starter pack of commercially avail-

able LED models is provided as part of the

module, which also includes the ability to

account for absorption of radiation in semi-

transparent solids such as a lens in front of

the LED, and the ability to simulate a circuit

board as a compact model with biaxial ther-

mal conductivity.

A company-specific LED model can also

be input and simulated by specifying for-

ward current for the LEDs. The software cal-

culates the correct thermal heating power

and a physically validated operating tem-

perature. It allows building of an accurate

thermal radiation analysis that is capable of

simulating absorption of radiation in semi-

transparent solids such as glass, as well as

taking into account effects such as refrac-

tion, specular ref lection, and wavelength

dependency (spectrum properties of the

radiation). Light

quality from the

LEDs can also

be calculated to

see whether they

meet the design

goals for light out-

put and uniformity.

The BUCK designers used the

FloEFD thermal simulation software embed-

ded in CATIA to meet the goal of designing

a new heat sink with vertical fins, a higher

airflow, and a self-cleaning effect that pre-

vents dirt deposition. By using the ther-

mal simulation software, they significantly

shortened the development time and were

provided with details they couldn’t other-

wise see to analyze their prototype. They

also were able to obtain the experience that

contributes to faster and better solutions of

future problems. The new heat-sink design

enabled the company to reduce the cost of

manufacturing and maintenance as well as

extend the product life. The company’s final

LED-based luminaire called Tangram (Fig.

4) also won a Good Design Award from the

Chicago Athenaeum Museum of Architec-

ture and Design.

ACKNOWLEDGMENT

The authors wish to acknowledge the support

received in writing this article from Mircea

Slanina, the responsible account manager

working with TRIAS microelectronics SRL, a

Mentor Graphics distributor.

FIG. 4. The final award-winning LED

industrial luminaire with the self-cleaning

heat sink.

1403leds_67 67 3/3/14 4:32 PM

Page 70: LED Magazine - March 2014

68 MARCH 2014 LEDsmagazine.com

last word

LEDs currently represent less than 0.1%

of the lighting waste stream. It will be

many years before lighting incorporat-

ing LED technology starts to be returned in

appreciable quantities. However, some are

already asking how these devices will be

recycled when they finally reach end of life.

LED producers should be aware that they

need to comply with the national Waste Elec-

trical and Electronic Equipment (WEEE)

legislation implemented in most European

Union member states. This involves joining

a collective WEEE compliance scheme, such

as Recolight. Obligations for members include

a duty to provide data regarding tonnages of

product put on the market, as well as recy-

cling their share of waste lamps.

However, the collection and recycling of

LED lighting products themselves is already

being considered in the European standard-

ization committee responsible for treatment

standards for waste electrical equipment.

Because they look the same as other

lamps, in many European countries LED ret-

rofits are collected along with waste fluores-

cent lamps, in the same containers.

Waste LED lamps are classified as non-haz-

ardous, whereas waste fluorescent lamps are

hazardous (because of the presence of mer-

cury). In the UK, the Environment Agency (EA)

has taken the position that waste LEDs and

fluorescent lamps can be commingled or “co-

collected,” despite existing requirements that

hazardous and non-hazardous wastes should

be separated. This is a logical and pragmatic

approach; the sorting of lamp waste by users

and recyclers is often difficult because fluo-

rescent, LED, and filament lamps often look

similar. Also, with such low levels of LEDs cur-

rently requiring recycling, user and recycler

sorting would be expensive and time consum-

ing. Furthermore, if LEDs were not put in the

GDL recycling container, they

might be put in general waste

and sent to a landfill.

Co-col lection helps to

establish an LED retrof it

waste collection process for

the longer term, when the per-

centage of LEDs in the waste

stream will rise.

Waste LED retrofits can

be recycled with other WEEE

because they do not contain

mercury. They are, in some ways, more sim-

ilar in nature to other WEEE than to fluo-

rescent lamps. Nevertheless, where they are

co-collected, they should be treated as mer-

cury-bearing lamps because there is a real

risk they may have some mercury contam-

ination. Breakages in waste-lamp contain-

ers may cause some fugitive mercury emis-

sions. Co-collected waste LED lamps would

therefore go through the same crushing and

separation process as for fluorescents. This

would not apply to waste retrofit LED tubes,

which are not suitable for crushing. These

do need to be separated, decontaminated,

and put through a general WEEE shredder.

This position is likely to be enshrined

within the draft waste-lamp treatment stan-

dard. However, the draft also states that waste

LEDs may be treated through a separate pro-

cess if collected as a single LED-only load (and

verified through the audit trail that confirms

no mercury contamination). This will allow

the standard to be relevant both now and in

the future when the level of LED waste lamps

is expected to grow.

LED products do contain

trace amounts of rare earths

(typically at picogram levels).

The quantities are so small

that there is currently no eco-

nomic incentive to separate

them out — and also no tech-

nology available to recover

them. However, ensuring LED

lamps are collected together

with fluorescent lamps means

that as technologies develop and economics

change, they can be available as a discrete

waste stream for appropriate treatment.

The proportion of LED luminaires cur-

rently arising as waste is negligible; they

only arise as returns to the producer now.

Wherever possible, waste LED lumi-

naires should be collected separately from

conventional luminaires. This is principally

because in the long term there may be value

in separating out the LED chips.

Luminaire recycling usually involves

some manual dismantling of the luminaire,

which is then placed through a WEEE

shredder (as it would be non-hazardous) to

separate plastics, metals, and other com-

ponents. These go on for further recycling

and recovery.

LED sources need to find a place in the recycling stream

Although LEDs boast the advantage of long operational life, the growth in solid-

state lighting means that LED producers and government agencies need to have

appropriate disposal plans in place, says NIGEL HARVEY, chief executive of the UK’s

WEEE-compliant recycling-service-provider Recolight.

1403leds_68 68 3/3/14 4:32 PM

Page 71: LED Magazine - March 2014

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Page 72: LED Magazine - March 2014

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