R&D efforts also revolve around improving heat dissipation and extending service life.
Greater luminous efficacy is the catchphrase in China’s high-power LED industry. A rising number of suppliers are developing models capable of more than 100 lm/W and
10W.
Many are also working on increasing the luminous flux. Dongguan Sourcechip Opto-Electrical Technology Co. Ltd has launched the SCP-8080D1W-1 model, which delivers 100 to 120 lumens.
Shenzhen Smalite offers 100W units, while Guangzhou Hongli Opto- Electronic Co. Ltd carries 50W variants in its catalog. The latter has also introduced types with 129.5 to 147.7lux, ESD protection and eutectic die bonding.
Suppliers are using new LED chips to increase luminance. They are also adopting more advanced COB and cooling technologies to create small versions with a longer service life and greater stability.
Guangzhou Hongli is working on a highly efficient, low-cost MLCOB light source. Scheduled for mass manufacture this year, the product has a baseboard made of porcelain to reduce outlay. The maker employs an in-house-developed plastic and surface high reflection process to solve heat dissipation problems.
Other enterprises are upgrading current heat dissipation methods or exploring new ones, using ceramic or aluminum for their substrate package.
With many technologies in the line owned by international players, more China companies are applying for patents to avoid IPR issues.
Makers are supporting R&D efforts with manpower training and management restructuring. A growing number of suppliers are pursuing the former to boost quality and operational efficiency. Dongguan Sourcechip is holding two training sessions per week this year to introduce personnel to the different aspects of manufacturing, including engineering and QC. It hopes to strengthen the management system to achieve greater productivity and profitability.
To address labor shortage concerns, enterprises are improving employees’ working and living conditions. Most raised compensation levels in hopes of attracting skilled professionals to fill managerial positions. They are also heeding the government’s call for higher salaries, specifically a yearly minimum wage rate increase exceeding 13 percent during the 12th Five-year Plan covering 2011-15.
China has more than 50 manufacturers of high-power LEDs, over half of which are located in the Pearl River Delta region. The rest are scattered in Zhejiang and Jiangsu provinces, and Shanghai.
The line is buoyed by robust exports to Asia, Europe, North America and the Middle East.
The bulk of suppliers reported strong sales last year. Zhejiang Z-light Optoelectronics Co. Ltd, for instance, saw its 2011 revenue climb 50 percent from 2010, prompting the hiring of additional employees to sustain the growth momentum. Also buoyed by surging LED orders, Shenzhen Smalite plans to expand production capacity for high-power variants in the months ahead.
To broaden their customer base and strengthen global presence, most makers are sponsoring LED forums and participating in trade shows. Zhejiang Z-light exhibited at the 8th China International Exhibition and Forum on Solid State Lighting in November 2011. It will join other exhibitions, including the LED China 2012 to be held in Guangzhou, Guangdong province.
Products for various lighting needs
China-made high-power LEDs are available in single- and multichip versions in white, warm white, amber, red, blue, yellow, green and RGB versions.
The majority of releases emit white, warm white and amber.
DIP and SMD are the most common configurations adopted. Buyers will find round, rectangular and welding plate. The standard diameters are 3, 4, 5, 8 and 10mm. Products support 1, 3, 5, 10, 15, 20, 30, 50 or 100W, with 1 to 30W units forming the bulk of output. Releases delivering 1W continue to be best-sellers.
Makers generally use high-power soldering machines, but many enterprises are turning to reflow soldering technology. The more intense wave peak or soak-stannum soldering process is likewise gaining traction.
The ZP-X1EL11W1-A0 model from Zhejiang Z-light is a 1W LED that emits warm white. Its body uses heat-resistant polymer while its lead frame is silver-plated, rendering the unit suitable for general, architectural, street and advertisement applications.
Dongguan Sourcechip mainly produces 1W variants with various luminance levels. Featuring a high luminous flux of 100 to 120 lumens, its SCP-8080D1W-1 model uses the Epistar 45-mil lnGaAlN chip with a wavelength of x0.31 and y0.31nm. This white diode has a yellow lens covering its exterior, 3 to 3.4V working voltage in constant current and 120-degree wide-viewing angle.
Guangzhou Hongli’s 12W HLLB019 model, which is designed for indoor lighting, has a CRI exceeding 70 and high luminous flux. It comes in a ceramic substrate package. The maker’s HL-C3535 model supports a heat resistance level of less than 5 C/W and measures only 3.5x3.5x1.8mm. It offers a good thermoelectric separation design at a low expansion coefficient. This unit is for indoor and outdoor decorative, and automotive interior and exterior lighting, and backlighting applications.
Most products from mainland China have a life span exceeding 50,000hr and come with a one- year warranty. They comply with CE and RoHS requirements, with some even carrying ETL, TÜV and EMC approval.
LED chips, wires and brackets are the key inputs for manufacture. The bulk of mainland companies source lnGaAlN or GaP LED ICs from local, Taiwan or US providers. The top chip suppliers include Epistar, Chimei, Bridgelux, Sanan, Arima and Formosa Epitaxy. For the wires, some enterprises use gold or gold alloy as it that can withstand extremely high temperatures, while others employ silver alloy bonding wires for cost concerns.
With raw material outlay dropping by 5 percent in the first few months of 2012, companies reduced quotes by 5 percent. Many anticipate further markdowns. LED IC spending is expected to slide in coming years as Taiwan and mainland chipmakers increase production capacity in response to soaring global demand.
Taiwan: Makers boost luminous efficacy
Taiwan high-power LED manufacturers are raising their products’ luminous efficacy, with some offering models supporting 160 lm/W at 300 to 350mA. Most companies have DIP and SMD types delivering 100W. White diodes are the best-sellers, particularly for lighting applications.
Shipments of SMD LEDs have been growing steadily in recent months. Such releases typically come in PLCC and chip configurations. The former variety is widely used in digital signage, advertisement light boxes, outdoor landscape lighting and industrial equipment.
Taiwan manufacturers also offer LED chips or packaging/modules. Several enterprises, including Edison Opto Corp. and Everlight, carry both chips and modules. The first, a major high-power LED chip supplier, offers high-power LEDs with 350mA or greater for lighting applications.
Makers are confident of strong growth in the years ahead on the back of the robust global industry. Worldwide shipments are forecast by the Industrial Economics and Knowledge Center to reach $18.9 billion by 2015. Taiwan’s LED lighting segment expanded by 124 percent in 2011, according to the Photonics Industry Technology and Development Association. High cost remains a major concern, but suppliers are increasing efforts to achieve economies of scale.
LED TV and lighting applications will continue to be the main growth drivers. The emerging trend for a single LED light bar in LED TV backlighting will spur the adoption of high-power diodes in this segment. The indoor and commercial lighting sectors likewise show promise given the gradual phase-out of incandescent bulbs and mandated shift to energy-saving alternatives in various regions. The US and Japan governments, for example, will cease producing the former type beginning this year. The EU has prohibited sales of 150W incandescent bulbs since 2008 and 60W incandescent bulbs starting 2009.
Medical, automotive and plant illumination could also boost LED use in coming years.
Increased exports of high-power LEDs have pushed down prices. Competition from low and medium-power diodes is also prompting manufacturers to lower quotes to grab more orders.
Read the full report on High-power LED makers enhance luminous efficacy & flux. Global Sources is a leading B2B portal and a primary facilitator of trade with China manufacturers and India suppliers, providing essential sourcing information to volume buyers through our e-magazines and trade shows.
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