Challenges and Opportunities for High Power White LED Development

Decai Sun, Ph. D DOE SSL R&D Workshop, Atlanta February 1, 2012
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Outline
Opportunities for Cost Reduction of High Power White LED Packages Solutions to Raise Performance of High Power Warm White LEDs

DOE SSL R&D Workshop, Atlanta, Decai Sun, February 1, 2012

LED Package Evolution in Philips Lumileds

100

Power handling per LED (W)

10

0.1

0.01 1960

1970

1980

1990

2000

2010

2020

Lead frame based HP LED packages Custom designed for non-general lighting applications
Portable, automotive, traffic signal and emergency vehicle lighting, etc

Lagging behind ceramic based HP LED packages in cost

DOE SSL R&D Workshop, Atlanta, Decai Sun, February 1, 2012

Low and Mid-Power LED Packages and COB

Low and mid-power LEDs are leading in the race of lm/$ approaching 400 lm/$
Standardized package design Lower package and die cost Improvement in efficacy High volume from BLU

5630 SMD, 0.5 W

COB package development

Scalable in size and light output Easy to manufacture and copy Simplify optical design and LED engine assembly

DOE SSL R&D Workshop, Atlanta, Decai Sun, February 1, 2012

Future Cost Reduction of High Power LEDs

Do we need to look beyond die on ceramic package for cost reduction?

What is the requirement or constraint? Thermal handling capability Light extraction/package efficiency Reliability and long life Lens-free LED package is preferred in certain applications Package innovation & standardization will help to drive down cost
DOE SSL R&D Workshop, Atlanta, Decai Sun, February 1, 2012

How to Close the lm/W Gap between WW and CW LEDs

DOE SSL MYPP 2011

The lm/W gap between WW LEDs and CW LEDs is up to 30% or more

How to close the efficacy gap?

Development of narrow red phosphors and QD materials Hybrid WW consisting of overlyconverted CW (OW) plus AlInGaP red LED

Photopic Response

CCT ~ 2700K
30nm FWHM red, 90 Ra, LE ~ 370 lm/Wopt

Spectral Power Distribution (noramalized)

today ~ 80 Ra, LE ~ 315 lm/Wopt

350

450

550
Wavelength (nm)

650

750

DOE SSL R&D Workshop, Atlanta, Decai Sun, February 1, 2012

Hybrid Warm White LEDs

Approach
InGaN OW LEDs plus AlInGaP direct red LEDs

Advantages
High efficacy High CRI High R9 CCT tuning

DOE SSL R&D Workshop, Atlanta, Decai Sun, February 1, 2012

Record Demonstration of WW LED by Epistar

216 lm/W at 2700K and CRI of 87 using OW plus HV red Chip size, operation temperature and color coordinates unknown

(Photo from 12/2010 Epistar report of 170 lm/W 2700K record)

(Source: Epistar website 12/2011)

DOE SSL R&D Workshop, Atlanta, Decai Sun, February 1, 2012

Opportunities for Hybrid WW LEDs

General: High efficacy High CRI warm white Retail: Tunable white for scene setting Food spectrum Hospitality: 2200 K warm white Warm dimming

DOE SSL R&D Workshop, Atlanta, Decai Sun, February 1, 2012

LED Engines Using OW plus Red LEDs

DOE SSL R&D Workshop, Atlanta, Decai Sun, February 1, 2012

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Dimming to Warmer White

2200K

2700K

DOE SSL R&D Workshop, Atlanta, Decai Sun, February 1, 2012

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Benefits of Hybrid WW LED in One Package

Compact LED engine by reducing footprint
More suitable for spot lighting

Cost reduction Better color uniformity

DOE SSL R&D Workshop, Atlanta, Decai Sun, February 1, 2012

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