MARCH 2014

+
LEDsmagazine.com

IP and patents
Phosphor technology
Q&A P.21

US DOE
Lessons learned
boost LEDs P.33

Simulation
TECHNOLOGY AND APPLICATIONS OF LIGHT EMITTING DIODES Thermal-electrical
SSL analysis P.65

UNESCO
Heritage Site
SSL highlights
architecture, limits
light spill P.26
 Light Years Ahead
Setting the Standard for Dimmer Compatibility

CS161X Family of Dimmable LED

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The CS161X family of digital LED controller ICs have been
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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.
LEDMAGFeb2014
 ISSUE 68

2014
March 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)

features
21 INTERVIEW
Intematix expands phosphor development and IP
to meet demanding SSL applications Maury Wright columns/departments

26 OUTDOOR LIGHTING
Regeneration throws light on Norman architectural
4 COMMENTARY Maury Wright
SIL talks foreshadow significant
heritage Caroline Hayes LED revenue growth

33 PROGRAMS
LED lighting progresses driven by lessons learned
9 NEWS +ANALYSIS
Red and warm-white LEDs
James Brodrick, US Department of Energy wash Rabat walls
GE Lighting and CRS
43 FOCUS ON
Auroralia Awards Maury Wright
Electronics settle suit
Cree expands high-density COB family

53 OPTICS Evolucia wins optics patent

Tertiary optics deliver benefits in SSL product Microchip acquires Supertex

design Suleyman Turgut, Luminit LLC Acuity announces EcoDrive
family from EldoLED

59 SCIENCE
UV-LED advancements extend the promise in
Lutron expands EcoSystem family
Sharp launches color-
curing Bill Cortelyou, Phoseon Technology tunable mid-power LEDs
Samsung LEDs target mobile devices
65 DESIGN FORUM
Simulation enables optimum LED streetlight
Osram adds color LEDs
for auto applications
heat-sink design Djordje Zivanovic, BUCK d.o.o., and
Richard Ozaki, Mentor Graphics Corporation
19 FUNDING + PROGRAMS

68 LAST WORD CSEM announces EU-funded LASSIE-FP7

large-area SSL module project
LED sources need to find a place in the recycling
stream Nigel Harvey, Recolight

LEDsmagazine.com MARCH 2014 3

commentary
SIL talks foreshadow
significant LED
revenue growth
A
t the 15th-anniversary Strategies in
Light conference held in Santa Clara,
California over February 2527, 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 didnt 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 companys 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, Crees
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
4 MARCH 2014
SENIOR VICE PRESIDENT Christine Shaw
& PUBLISHING DIRECTOR cshaw@pennwell.com
EDITOR Maury Wright
mauryw@pennwell.com
ASSOCIATE EDITOR Carrie Meadows
carriem@pennwell.com
CONTRIBUTING EDITOR Caroline Hayes
caroline.hayes@ruivamedia.com
MARKETING MANAGER Kimberly Ayer
ART DIRECTOR Kelli Mylchreest
PRODUCTION DIRECTOR Mari Rodriguez
SENIOR ILLUSTRATOR Christopher Hipp
supplied internally in the case of vertically- AUDIENCE DEVELOPMENT Debbie Bouley
integrated LED manufacturers. Japan at
21% and Korea at 15% were the next largest
sources of LEDs for lighting.
EDITORIAL OFFICES PennWell Corporation,
Meanwhile, Strategies Unlimited said LEDs Magazine
98 Spit Brook Road, LL-1
retrofit lamps will become the largest near- Nashua, NH 03062-5737
term consumer of LEDs in SSL, and A-lamps Tel: +1 603 891-0123
Fax: +1 603 891-0574
will lead the way despite the call for innova- www.ledsmagazine.com
tive new form factors that fully leverage LED
SALES OFFICES
sources. Evstratyeva said that in 2013 there SALES MANAGER Kelly Barker
were 100M (million) LED retrofit lamps sold. (US EAST COAST) kellybarker@Pennwell.com
Tel. +1 603 891 9186
That sounds impressive until you consider SALES MANAGER Allison OConnor
that there are 50B sockets installed globally. (US WEST COAST) allison@jagmediasales.com
Tel. +1 480 991 9109
In the lighting segments discussion, it was SALES MANAGER Jim Ajayi
the projected breakdown of the LED types to (EUROPE) jima@pennwell.com
be sold that perhaps was most surprising. In Tel. +44(0) 1992 656657
SALES MANAGER Holger Gerisch
recent years, weve heard about low-cost mid- (FRANCE/GERMANY/ holgerg@pennwell.com
power LEDs taking over in lighting, and that AUSTRIA/SWITZERLAND) Tel. +49 (0) 8856 8020 228
SALES MANAGER Masaki Mori
would seem an appropriate trend in the cost- (JAPAN) mori-masaki@ex-press.jp
sensitive lamps market. But Evstratyeva proj- Tel: +81 3 3219 3641
ects that low-and mid-power LEDs combined SALES MANAGER Mark Mak
(CHINA & HONG KONG) markm@actintl.com.hk
would, by 2018, only account for 35% of the Tel: +852 2838 6298
LEDs sold into lamps based on component SALES MANAGER Monica Liu
(TAIWAN) monica@arco.com.tw
revenue. The actual number of components Tel: +886 2 2396 5128 ext: 270
shipped would tell a far different story. SALES MANAGER Young Baek
Mid-power penetration will be greater (KOREA) ymedia@chol.com
Tel: +82 2 2273 4818
in commercial and industrial applications. SALES MANAGER Dan Aronovic
The mid- and low-power segment will (ISRAEL) aronovic@actcom.co.il
Tel: +39 972 9899 5813
account for about 50% of revenue by 2018.
CORPORATE OFFICERS
High-power LEDs will go from 50% in 2013 CHAIRMAN Frank T. Lauinger
to 15% in 2018. But superhigh-power, which PRESIDENT AND CEO Robert F. Biolchini
includes chip-on-board (COB) LED arrays, CHIEF FINANCIAL OFFICER Mark C. Wilmoth
will represent 35% of the revenue in 2018. TECHNOLOGY GROUP
SENIOR VICE PRESIDENT Christine A. Shaw
Lower-power penetration will be driven by & PUBLISHING DIRECTOR
linear applications such as ceiling troffers. SUBSCRIPTIONS: For subscription inquiries:
Tel: +1 847 763-9540;
Those in the audience at Strategies in Fax: +1 847 763-9607;
Light surely saw opportunity in the many e-mail: LED@halldata.com;
ledsmagazine.com/subscribe
presentations that the conference com-
We make portions of our subscriber list available to carefully screened
prised. It will be a fun five years watching 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
the jockeying for leadership positions. via direct mail, please let us know by contacting us at List Services
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Maury Wright, EDITOR form without prior written consent of Publishers.
mauryw@pennwell.com
LEDsmagazine.com
 We bring quality to light.

DISCOVERING
LIGHT
More at Light + Building
2014

Putting LEDs in the right light.

SSL solutions from the world leader in LED measurement

Right from the start, we have been supporting the

LED industries with our measurement equipment.
You will also benet from this expertise in the new
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with new features
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 FEATURED events
| online LEDucation 8
March 1819, 2014
New York, NY

Editorial Digest Phosphor Global Summit 2014

March 2628, 2014
LED modules advance SSL San Diego, CA

developments and light quality Photonics21 Annual Meeting 2014

http://bit.ly/1k9nm2e March 2728, 2014
Brussels, Belgium

Light+Building 2014
March 30April 4, 2014
Webcasts Frankfurt, Germany

SSL 2014: LED technology Asian Lighting Exhibition (ALEEX) 2014

April 1417, 2014
advancements accelerate Guangzhou, China
the lighting revolution
Gulf LED Exhibition
http://bit.ly/1ptNplg April 2224, 2014
Abu-Dhabi, United Arab Emirates

Understand LED driver design and dimming RadTech UV & EB Technology

Expo & Conference 2014
techniques that can deliver optimal SSL products May 1214, 2014
http://bit.ly/1pqlJhe Chicago, IL

Lightfair International 2014

White Paper June 35, 2014
Las Vegas, NV
Materials Matter:
The LED Show
The Material Selection Process September 1618, 2014
http://bit.ly/1fHNddX Los Angeles, CA

MORE: ledsmagazine.com/events

ADVERTISERS index
Aamsco 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

6 MARCH 2014 LEDsmagazine.com

 The spotlight shines on efciency.

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 thats
superior to passive heat sinks and raises performance while reducing the size of
the lighting xture. 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 nd out more about custom Active Cooling
Solutions, visit info.ebmpapst.us/ActiveCooling. The engineers choice
 LED BRIGHTNESS THATS

TOO GOOD
TO BE TRUE
Introducing the Acrich MJT 4040
High-Voltage LED
Using our patented Multi-Junction
Technology, the MJT 4040 offers
increased brightness and light density
perfectly suited for your next
outdoor LED application.

www.seoulsemicon.com

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

 +
news views
HERITAGE LIGHTING
Red and warm-white
LEDs wash Rabat walls
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 Rabats 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 Schrder 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-
BUSINESS AND IP
GE Lighting and CRS
Electronics settle suit
GE 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 Lightings intellectual property across the globe.
LEDsmagazine.com
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
PACKAGED LEDs
Cree expands high-density
COB family
Cree 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
Crees 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
MARCH 2014 9
news+views
Rabat from page 9 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
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; thats 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 67
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.
10 MARCH 2014
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 Crees 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 cant 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
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
Nmes, France that included pedestrian tun-
nel lighting and roadway lighting mounted
in curbs (http://bit.ly/LImuCK). The Nmes
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.
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
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.
LEDsmagazine.com
 Thomas Research Products
SSL Solutions Faster Than The Speed Of Light

NEW!
DC LED Light Engines For
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From the Authority on LED Power

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drop into a wide variety of existing luminaire form factors. A complete
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lumen output and long life. These models are optimized for TRPs
comprehensive line of high performance LED drivers.
We capitalize on our experience in the
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2014
news+views
STs 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 companys 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 010V 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
12 MARCH 2014
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 dont
need to redirect the light path with optics,
which creates inefficiencies.
Microchip acquires Supertex
Microcontroller specialist Microchip
Technology has acquired analog and mixed-
signal IC manufacturer Supertex includ-
ing the latters 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. Supertexs 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
Supertexs business with Microchips ana-
log business will enable significant syner-
gies and cross-selling opportunities.
MORE: http://bit.ly/1gwJ36M
LEDsmagazine.com
from inspiration...

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 news+views
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, Acuitys
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
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The new drivers target indoor applications
and are based on a digital-power-control
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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
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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 companys 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
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www.proled.com

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 27006500K. Sharp will demonstrate
the compact 4.230.9-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 1215-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
LEDsmagazine.com
news+views
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
flash applications, one LED in a flip-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 reflector-based
designs in a 3432 package that stands
MARCH 2014 15
news+views
1.8mm 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-
16 MARCH 2014
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 1.51.90.7-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 100C, 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
LEDsmagazine.com
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programs
CSEM announces EU-funded LASSIE-FP7
large-area SSL module project
The CSEM (Centre Suisse dElectronique 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,
LEDsmagazine.com
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 Europes 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.
MARCH 2014 19
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interview | PHOSPHOR IP

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, Intematixs latest developments and patents, and applications from LEDs to
backlighting to remote optics.

P
hosphor 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 Phosphor formulations such as those from Intematix are central to manufacturing LEDs.
major IP stakes in the area. Since Intematix
also supplies phosphors to LED manufac- 5,998,925, commonly called the 925 patent. phor-converted LEDs or remote-phosphor
turers we took the opportunity to question As market research firm Yole Dveloppe- SSL products would not require licenses
Julian Carey, senior director of marketing, ment points out, while LED phosphor IP is to Nichia or Osram phosphor patents (http://
on the state of the phosphor IP space. complex and rich with thousands of patent bit.ly/1gXh5CS). Have you developed a cus-
families, only a few patents have provided tomer base for those patents among LED
LEDs Magazine: Can you give us a significant returns to their owners in terms manufacturers or has the primary usage
quick foundation as to the history of phos- of market share, freedom of exploitation, been in remote phosphor applications?
phor-oriented patents that are both directly or additional revenue streams from royal- Carey: Today, Intematix is one phosphor
focused on LED products and perhaps that ties. Some of those patents are on the verge maker that is further addressing the
are more general in nature if there is an of expiring within the next 5 to 10 years trend toward high-quality light with its
impact on SSL? most notably, Nichias 925 patent, which is patented, advanced phosphor technology.
Julian Carey: High-brightness LEDs set to expire in 2017. In addition to being the only company
were originally developed around the 1990s that makes the patented GAL formulation,
by early producers of gallium nitride (GaN)- LEDs Magazine: Intematix announced Intematix patents also cover different
based blue LEDs in Japan after researchers its green GAL (green aluminate) phosphor wide-spectrum green phosphors called
from Nichia and a professor from Nagoya back in 2010 and touted it as an alternative LuAGs (for lutetium-aluminum-garnet).
University shared their formulation. The to YAG and other licensed phosphor formu- GAL generally offers a broader spectrum,
combination of blue LED chips with YAG lations. Indeed, at the time the company spe- higher thermal stability, higher CRI, and
(yttrium aluminum garnet) phosphor was cifically said that its customers and we higher quality of light compared to LuAG
patented by Nichia in 1996 via US patent No. assume that means customers making phos- formulations, but owning IP that covers

LEDsmagazine.com MARCH 2014 21

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
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.
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,
todays 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
200C with GAL, you will only lose a very
small degree of brightness this very high
22 MARCH 2014
The ChromaLit linear remote-phosphor optic from Intematix.
degree of stability means that manufactur-
ers can drive their LEDs harder and realize
lower costs using fewer LEDs.
LEDs Magazine: While this isnt 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, its 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 doesnt contribute that much to
the overall solution cost. Thats 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 Chinas actions, now
were seeing additional sources pop up all
over the world. Since its really not a monop-
oly anymore, were 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 companys 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.
LEDsmagazine.com
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 interview | PHOSPHOR IP

LEDs Magazine: We understand, as you phosphor there have been continuing ques- linear application segment have a coating
said, that some of the most basic patents in tions as to whether your customers making that allows the products to appear white in
the phosphor area will expire in the coming SSL products with your ChromaLit optics the off state and therefore potentially appeal
years. As we discussed, the Nichia 925 patent might need license agree- more to lighting designers/
will expire. How will such an event impact ments with other compa- specifiers. What is the IP
the phosphor industry? Most of the major nies. Cree in particular has behind that technology? Is
LED manufacturers have cross-licensing said that any company mak- that a phosphor story or one
deals in place so it seems the impact there ing remote phosphor lamps based on yet another type of
might be minimal. But could it shake up the or luminaires needs to have a materials? Do you expect to
industry in other ways? cross-licensing agreement in patent that technology?
Carey: The expiration of the Nichia pat- place. You have insisted thats Carey: W hile we do
ent will remove a significant barrier and not the case. What is your have patents covering lin-
will allow broader use of the YAG materi- stance and how are you stand- ear remote phosphor, the IP
als covered by the patent. Patent activity ing behind your customers? Julian Carey, Intematix pertaining to the off-state
remains strong and it is now focused on Carey: Intematix is very appearance of our new lin-
emerging compositions, mostly addressing confident regarding its remote phosphor ear product would fall more into the trade
the need for more efficient and cost-effec- IP and stands behinds its remote phosphor secret area. The way the technology con-
tive red and green phosphors to be used in products. In fact, not only will Intematix ditions the light going into the optic dif-
display and general lighting applications. cover legal costs in the event of an infringe- fers from that exiting, which is why it shows
Differentiation opportunities remain, and ment litigation regarding its products, good appearance without affecting light
the development of any new compositions but it will also take responsibility for the output too much. Different types of inno-
with disruptive potential could still greatly defense of any such litigation. vations may be best served in our business
benefit its inventor. LEDs Magazine: Also with regard to with different IP strategies and these are
LEDs Magazine: In the area of remote remote phosphor, your latest products in the matters we consider to great extent.

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outdoor lighting | ARCHITECTURAL
Regeneration throws
light on Norman
architectural heritage
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 buildings features
while project specifiers remain sensitive to the architectural integrity of the monument as well as
potential light pollution concerns.
I
n the north of England, the town of
Durham is guarded by dual, imposing
monuments its castle and the citys
cathedral. As the 25th anniversary of the
castle and cathedrals 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
CAROLINE HAYES is a contributing editor with
LEDs Magazine.
26 MARCH 2014
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 flat 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 The LED-lit entrance
also for the Pipistrelle and Natterer bat pop- to Durham castle.
ulations locally.
LEDsmagazine.com
The new solid-state
lighting system
accentuates some of
the historic stonework
at Durham Castle.

Landmark lighting
Stainton Lighting Design Services and Urbis
Schrder 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 areas
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 39
ft) from the buildings. The closer positioning also
eliminated the need for additional window reveals

LEDsmagazine.com MARCH 2014 27

 The Norman architecture
of Durham Castle and
Cathedral, seen from the
city of Durham below.

as the new system produced less light spill Stainton specified the combination of wide, replacements to be provided with the exact
into the buildings windows. This was a medium, and narrow, and horizontal and same characteristics.
particular benefit in the castle keep and the vertical beams, including those with 90 for Some of the detail that the lighting made
parts of the cathedral that are used for stu- a low horizontal line or a long vertical line on more prominent was commented on by long-
dent accommodation. particular areas. For each floodlight, a spe- term members of castle staff, who reported
The proximity of the customized Urbis cific position was designated, with a specific that they had not noticed some of the inter-
Schreder Neos 1, Neos 2, and Noctis 225 LED lens combination. esting stonework features before.
floodlights and bespoke Philips eW Reach Despite the options and configurations, Part of the design concept regarding dis-
floodlights serve to highlight the fabric and all variances in color temperature were tant views of the buildings was to provide
fine masonry work of both buildings without within 100K. The customization was also a subtle but observable contrast between
being visible themselves. Paul Johnson, Urbis practical. Smith points out that although the color temperature of the castle and the
Schreders regional sales manager, north of the specification for each luminaire was cathedral. Two color temperatures were
England, explained the pains that the project bespoke, the selection of LEDs will allow selected for each building 3000K and
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.

Less light spill throughout the property

benefits the students boarding in the
castle keep quarters during term time.

28 MARCH 2014 LEDsmagazine.com

 9th Replacement

3rd Replacement
5th Replacement

12th Replacement

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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
30 MARCH 2014
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 cathedrals 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.
LEDsmagazine.com

Despite more luminaires being used than in
the original lighting scheme, the target of 33%
energy savings was surpassed.
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
LEDsmagazine.com
Solder and
Fluxes for LEDs
was decided upon. This is one of the most Solder
common protocols used with LED technol- Paste
ogy and offers control and flexibility, says
Smith. Johnson believes this is the first part-
wireless DMX implementation.
Luminaires were grouped into zones that Flux-Coated
Preforms
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- Flux
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, Thermal
were sent over the building and around with Interface
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 NanoFoil
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- Learn more:
cific lighting sequence. There are five to six http://indium.us/F313
programs set in the control HQ sited in
one of the cathedral offices and the porters
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 www.indium.com
would achieve energy savings of 60%. The askus@indium.com
final installed lighting will save approxi- ASIA CHINA EUROPE USA
mately 18,500 (around $30,360) per year
in energy costs at todays prices, he says. 2014 Indium Corporation
MARCH 2014 31
programs | DOE SSL

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.

S
olid-state lighting (SSL) implications for the future. The
has made impressive prog- result is a compilation of analysis
ress over the past decade, and recommendations for consider-
emerging as a promising new tech- ation by manufacturers, standards
nology that could fundamentally organizations, energy-efficiency
alter and improve lighting systems, programs, retailers, specifiers, and
and significantly lower energy use other stakeholders intended to
and costs. Benefiting from lessons stimulate further discussion and
learned from the market introduc- to aid in the continuous course
tion of compact fluorescent lamps corrections needed to achieve SSL
(CFLs) in the 1980s and 1990s, technologys full potential. The
actions taken by the US Department report is available online at www.
of Energy (DOE) in Gateway, Caliper, ssl.energy.gov/tech_reports.html,
Lighting Facts and other programs and we will examine some of the
(Fig. 1); energy efficiency programs; key lessons here.
and standards organizations have
helped industry avoid some of the Lesson 1: Rigorous testing require-
problems that plagued CFL mar- ments adopted in the early days of
ket development. Still, the lighting SSL development were necessary to
industry faces challenges in the SSL counter exaggerated claims of per-
transition and can continue to ben- formance by some manufacturers,
efit from lessons learned in the early but they eventually led to unreason-
stages of SSL deployment. ably high testing costs.
Efforts by the DOE and other The exploding number of prod-
organizations have positively ucts and product variations com-
impacted the experience of LED- ing to market has created a test-
lighting adopters. Indeed, the adop- ing burden that can boost product
tion of LED lighting is happening far prices and slow product introduc-
faster than did the adoption of CFLs, tions, which in turn can slow mar-
FIG. 1. Shown is an example US DOE Gateway installation
although not nearly as fast as some ket adoption and associated energy
consumer electronics technologies
with solid-state lighting from Spring City Electrical in New savings. Family grouping policies
(Fig. 2). The success is in part due
York's Central Park. have been the primary means used
to standardized testing, minimum by energy-efficiency programs for
performance and reporting requirements, whose products perform well. addressing the testing burden issue.
and publication of testing and demonstra- Looking ahead, however, the full perfor- The voluntary qualification and listing
tion results that have made it more difficult mance and energy savings potential of SSL groups such as the DesignLights Consor-
for poor-performing SSL products to remain is far from realized or assured. With that tium (DLC), Energy Star, and DOE LED Light-
on the market, and rewarded manufacturers in mind, the DOEs new report, Solid-state ing Facts should consider increased coor-
lighting: Early lessons learned on the way to dination to continue to reduce the testing
JAMES BRODRICK is the lighting program market," analyzes actions taken thus far and burden on manufacturers, while maintaining
manager at the US Department of Energy. identifies challenges, new lessons, and their the integrity of product data through random

LEDsmagazine.com MARCH 2014 33

programs | DOE SSL

verification testing. In addition, the Market share (% of units) ier to specify various LED prod-
lighting community should con- ucts in the same space. Revised,
8
sider continuing to seek methods Smart new, or additional color rendering
and strategies to reduce the overall 7 phone metrics are needed to accurately
testing burden on manufacturers, 6 characterize the color rendering
as confidence in LED performance 5 2013: After 6 years capability of all light sources.
continues to increase. 1980: Philips releases LEDs have reached
4 frst commercial CFL
LED a market share of Lesson 5: The color delivered
3 2007: LSG releases over 4%
Lesson 2: Despite the promise of frst viable LED by some LEDs shifts enough over
long life, theres no standard way 2 replacement bulb time to negatively impact adop-
1986: After 6 years
to rate the lifetime and reliability 1 on the market, CFLs tion in some applications.
of LED lighting products. CFL had only reached The ability of LED lighting
0
Variability in lifetime and reli- 0 1 2 3 4 5 6 a penetration products to maintain chroma-
Years since market introduction of <0.1%
ability of similar products needs ticity over long lives has been
to be reduced to improve mar- demonstrated by the DOE L Prize
FIG. 2. The uptake of LED lamps is much steeper than it was for
ket adoption of LED products. winner, but not all products per-
CFLs but trails the pace of consumer electronics products such
There are many sources of fail- form at that level, and perfor-
as mobile phones.
ure in SSL products that must mance can vary significantly
be accounted for (Fig. 3). Uncer- (Fig. 4). Color stability measure-
tainty is slowly being reduced, as efforts a range of lamps or luminaires with similar ment and prediction methods are needed to
are made to standardize methods for pre- appearance, but with different photometric enable performance comparisons between
dicting lifetime and reliability. Standards performance. When an LED lighting product LED lighting products. Theres a need for
developers are working on new tools and is superseded by one with greater lumen out- energy-efficiency programs and product
metrics, some of which will still be limited put, manufacturers should consider keeping information qualification standards that
in their usefulness, but these tools and met- both in the product line. Developing one or include color stability metrics.
rics are needed to address this challenge. more forms of relative testing standards may Efforts to establish new methods and met-
Some manufacturers are providing longer help manufacturers manage the cost of test- rics for color stability assessment should
warranties for products serving key applica- ing product families. continue. With standards and metrics, color
tions and market sectors, which represents shift can rightfully be included in a yet-to-
another way to overcome uncertainty. Inno- Lesson 4: The range of color quality avail- be-developed comprehensive lifetime rating
vative product designs and increased use of able with LED lighting products, and the
lighting controls may further complicate the limitations of existing color metrics, may Driver
measurement and reporting of LED product confuse users. (control circuit)
7%
lifetime and reliability in the near future, While the availability of LED products
and all market actors need to work together with a range of color qualities may be an LED package
10%
to explore the effect of such features on life- asset in one sense, the variability also
time and reliability, as well as educate users. presents a number of challenges. Address-
Driver
ing these challenges will require a range (power supply)
Lesson 3: Although specifiers prefer com- of coordinated industry efforts. Retailers Housing
52%

plete families of products, the rapid evolu- should continue their efforts to provide 31%
tion of LED technology presents a challenge clear information regarding color quality,
to manufacturers in creating and maintain- especially the difference between CCTs.
ing complete product lines. Efforts to improve the consistency of infor-
Specifying families of luminaires allows mation on product packaging should also
for a consistent look and feel throughout continue, and industry should establish
a space and can also standardize mainte- effective color communication tools to sim- FIG. 3. The chart depicts the distribution
nance and spare parts. But manufactur- plify product selection. of 29 failures over 34 million operating
ers sometimes lack the time to develop full At the same time, the lighting research hours for one manufacturers family
product ranges, or find it difficult to keep community should consider establishing of LED outdoor luminaires (source:
products consistent with one another when performance criteria for color rendering that Appalachian Lighting Systems). Because
LED packages and drivers are changing so will ensure acceptability to a majority of LEDs are just one component out of
rapidly. Without the option of product fam- users. Standards organizations should con- many that can cause failure, a DOE-led
ilies, some specifiers may have trouble using sider establishing tighter tolerances for chro- industry working group recommends a
LED products across their projects. maticity bins, to reduce product-to-product systems approach to solid-state lighting
Manufacturers should consider providing variability at the same CCT, making it eas- lifetime and reliability.

34 MARCH 2014 LEDsmagazine.com

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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 flicker 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
New lamp 4000 hr lamp
5300 lux @ 1.26m 5300 lux @ 1.26m
FIG. 4. A new lamp and an identical product after 4000 hours of operation show what
would be unacceptable color shift in many applications.
and when dimmed, accounting for depen- of neurological impacts, and degradation in
dencies on the selection of control equip- task performance for different applications.
ment if applicable. The lighting research
community should consider conducting Lesson 7: LEDs can cause glare, which
research to establish thresholds for detec- may negatively impact adoption in some
tion of (and perhaps objection to) flicker, risk applications.
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
dont 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 isnt 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 theres 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
 Professional Power
programs | DOE SSL

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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 High Power CLH driver
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. IP66
RATED
VER

LE

Early experiences with some LED lighting products has shown that,
AB

IO
N AVAIL
while the LED packages themselves may be long-lived, driver failure or
S

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 tomorrows products will perform better than
todays can make it hard for lighting designers to decide when to start
specifying LED products. Luminaires designed with interchangeable
www.HarvardEng.com
components, such as LED modules or light engines, allow users to
USsales@harvardeng.com | Tel: 858-546-2834
take advantage of evolving LED technology by, for example, easily
upgrading to deliver higher efficacy or the ability to control color

LEDsmagazine.com MARCH 2014 39

programs | DOE SSL
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
COB ARRAYS
Technology that Xceeds your every Xpectation.

  

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-
DISCOVER A BETTER QUALITY OF LIGHT
MID POWER LEDS
ities, energy-efficiency programs, retail-
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ing quality, and cost considerations. Testing
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focus on Auroralia Awards
Sustainable Lighting
At the Light Festival on December 7, 2013 in Lyon, France, lighting manufacturer Schrder
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 Schrder identified urban projects in
Nmes, 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.

Nmes, France
The city of Nmes and transportation authority Nmes
Mtropole 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
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
Cntrica located at the foot of the Imbabura Volcano.
The 240,000-m 2 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%

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

LEDsmagazine.com MARCH 2014 43

focus on
energy savings compared to if the park had been lit
with legacy sources. The jury panel was impressed
with the citys 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- heating supplied by renewable sources. The outdoor lighting sys-
ing the iconic architecture while also protecting the local environ- tem will feature a comprehensive network for preventive mainte-
ment including preservation of the roosts of Pipistrelle bats. The nance and adaptive control based on the Owlet system, and LED
jury panel lauded the lighting design for using a DMX control sys- 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
tem and tunable lighting as it simultaneously limited the effects recover the cost and pre-
to mostly white hues that maintained the historical aesthetics and sumably make a profit
improved the visitor experience. over the 10-year term
of a maintenance con-
tract. The installation
Heidelberg, Germany also includes a network
Heidelberg, Germany nominated the redevelopment of an indus- that enables adaptive
trial area into a mixed-use business, entertainment, and residen- control and automatic
tial district that will include a comprehensive environmentally- meter-reading capabil-
friendly footprint ranging from lighting to water use to power ity for accurate deter-
generation. The Bahnstadt project will ultimately be larger than mination of power
the old city or Altstadt area and will include living space for a pop- usage. Sabadell projects
ulation of 5000 and 7000 jobs. The development will rely on pas- energy savings equal to
sive house standards as a construction method and district-wide 1,040,000 ($1,431,000)

44 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
worlds 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
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 MinelSchrder for refurbish-
ment with Schrders 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 citys 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
faade 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
installed a network for control and automated maintenance. The tour of the Grand Place project and see a dynamic night-time pro-
baseline energy savings of the project are 70% and that figure could gram. Ironically, some of the jury questioned the justification for
be increased through dimming the LED luminaires. The city also the use of colored lighting in the project and the value it brought
projects 75% savings in maintenance costs. But perhaps the most to visitors. Others felt that the color programs could increase tour-
impressive result is the light quality. The city staggered brightness ism and boost the economy, more than covering the price premium
by zone to help drivers adapt to lighting changes
with the time of day. Furthermore, the system
uses an asymmetrical beam distribution that
The Auroralia jury was composed of journalists that cover the
directs the lighting with the flow of traffic and
eliminates driver glare. For more information on sustainable lighting space from a variety of angles ranging from enabling
the challenges and benefits of LED tunnel light- technologies such as LEDs to urban planning. The panel included Maury
ing, see our recent feature (http://bit.ly/1h6yasK). Wright of LEDs Magazine, Paul James of Mondo Arc , Britta Hlzemann
of Licht , Charlotte Fauve of Ecologik , Albert Punsola of Ciudad
Mostar, Bosnia/Herzegovina Sostenible , Tom Rampelberghe of Light Partner , and Olivier Namias of
Lux. There were no firm rules that guided the judging process but rather
Effective LED-based lighting projects arent
just for major cities, as witnessed by the Mostar lengthy discussion interspersed with multiple rounds of balloting. The
project that covers the Old City area and the panel considered 26 city projects from Los Angeles to Russia to India.

46 MARCH 2014 LEDsmagazine.com

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; Sifok, Hungary; Setbal, Portugal; Rio de Janeiro,
Brazil; Passau, Germany; Pocking, Germany; Medelln, Colombia;
Mlaga, 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 for the RGB fixtures. In any event, the LED lighting is 80% more
includes a mix of LED and compact fluorescent (CFL) lighting efficient than the former lighting in the plaza and reduced main-
for landscapes and tenance cost by a factor of four.
building exteriors.
The Cairo entry had
perhaps the broadest Jyvskyl, Finland
array of different The Kuokkala Bridge had undergone a retrofit of the architectural
lighting applications and faade lighting back in 2002, but until recently the roadway
and fixture types in the was lit by globe-shaped luminaires housing HPS lamps. The city of
competition. Jyvskyl and its citizens liked the globes that had become a rec-
While there were a ognizable element of the bridges architecture, but sought a more
few new developments
among the entries such
as Cairo, more typically
the projects were
retrofits. For example,
Sifok 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 energy-efficient lighting option. Indeed, the bridge was arguably
annually to 46,000 kWh. overlit with inefficient sources. The city ultimately replaced the
Setbal is another example of a project that used a mix of fixtures with luminaires from Ketonen Oy that integrate an LED
LED and HID lighting. The city used high-pressure sodium (HPS) light engine from Valopaa Oy and new globes made by Elkamet.
to light some of the arterial roadways. But the downtown area The city determined that the bridge needed a light level of 1 cd/m 2
is lit with LEDs and the city says that the project has resulted in and the installation delivers 1.5 cd/m 2 using 3000K warm-white
its citizens making greater use of parks and walkways after dark. sources. Even though cooler sources would have been more effi-
The new lighting maintains a historic look, and the city is saving cient the city is still realizing 74% energy savings that will yield an
266,727 kWh annually. Indeed, the Auroralia Awards drew many 11-year payback. The bridge was part of a broader city plan called
noteworthy projects that both boost quality of life for residents Environmentally Friendly Outdoor Lighting that among other
and help trim global energy use and carbon emissions. things has seen streetlights upgraded and networked.

48 MARCH 2014 LEDsmagazine.com

 Bkscsaba, Hungary
Bkscsaba nominated a downtown modernization project centered
around Szent Istvn 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
Its a Snap.
Innovative holders with snap-in LED retention for simple and fast installation.
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2014 TE Connectivity Ltd. family of companies. All Rights Reserved. LUMAWISE, TE Connectivity
and the TE connectivity (logo) are trademarks.
Terra Maxi LED fixtures from Schrder. 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
focus on

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.

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optics | SSL DIFFUSERS

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.

W
hen the use of tertiary optics or FIG. 1. A GE Lighting PAR38 the secondary optic is
diffusers is an after-thought in lamp with a tertiary optic. a TIR-based collima-
the design of lamps and fixtures, tor. The tertiary optic
the designer ends up facing many integration Tertiary optic is an interchangeable
and performance issues after project comple- examples accessory that is eas-
tion. Conversely, tertiary optics can deliver One example of a ily replaced by the
many benefits in LED-based lamp and lumi- real-world product that customer in the field.
naire design when conceived at the start of the has all of these optical com- The accessory kit also
product development. Lets discuss the con- ponents is GEs LED PAR38 includes a linear spread
cept of collimate then diffuse for solid-state lamp (Fig. 1). The LEDs with optic that provides for lin-
lighting products and review real-world exam- the primary optic are ear or elliptical illumination
ples. We will consider various formats of ter- positioned at the base patterns at the target plane.
tiary optics like film, rigid panels, and injec- of the lamp; a reflec- The easy and flexible use of
tion-molded parts along with a discussion on tor surrounds the tertiary optics of different
how high- and low-performance optics differ. LEDs with a circu- kinds was what the designers
LEDs have introduced a greater level lar Fresnel lens posi- of the product had in mind from
of complexity to fixture and lamp design. tioned at the output the outset. As a result, the design of
Lighting designers have had to learn new aperture. Both the reflec- the secondary optics and the heat sink
techniques to control the light from these tor and Fresnel lens are considered to be sec- were optimized for use with tertiary optics.
new light sources, as well as new terminol- ondary optics. A diffuser is placed on top of One last example is an LED architectural
ogy associated with these techniques. While the Fresnel lens to clean up non-uniformity lighting fixture (Fig. 3). Here the secondary
the radiation from a bare LED with a pri- caused by the Fresnel structure and adjust optic is again a TIR- or parabolic-reflector-
mary optic can be fairly wide (8090), it is the beam to medium and flood angles. based collimator. The tertiary optic is an
considered to be directional when compared Another example is an LED recessed interchangeable accessory that is installed
to a conventional source like an incandes- downlight (Fig. 2). Here the secondary in the field and serves two functions: to
cent filament. In projection applications optic is the reflector that colli- mix the red, green, and blue com-
where the target plane of illumination is mates the radiation from the ponents of the illumination in air
more than 0.5m distant, the directional LEDs and the tertiary optic before hitting the target plane,
nature of an LED is not alone sufficient for is a diffuser that increases and to shape the beam
most lighting uses. Indeed, a secondary optic the beam angle as well pattern. Architectural
such as a total internal reflection (TIR) lens performing a hiding lighting installations are
or reflector is required to collimate the function that pre- typically complex for two
beam to somewhere between 3.515. A ter- vents someone from main reasons. First,
tiary optic such as a diffuser can also be seeing the LEDs the distance of the
required to improve the color and/or spa- under direct view- fixture from the
tial uniformity as well as shape the beam to ing conditions.
suit the photometric requirements. In the M R16 - FIG. 2. A
lamp sector, Soraa typical LED-
SULEYMAN TURGUT is director of sales, relies on yet a differ- based recessed
Luminit LLC. ent structure. Here downlight.

LEDsmagazine.com MARCH 2014 53

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-
54
tions these fixtures require very narrow
beam angles (e.g., 13.5) 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 lets 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 FIG. 4. The same fixture with different
diffuser to double as the window of the fix- tertiary optics delivers vastly different
ture or lamp and the tertiary optic. lighting effects (images courtesy of City
Polycarbonate is the preferred plas- Theatrical).
tic of choice for lighting applica-
tions. Its available in UV-stable the diffusion mechanism. High-performance
versions for outdoor applica- holographic diffusers incorporate a sub-
tions and in UL-listed versions micron surface relief pattern on top of a very
to meet flammability require- clear substrate. Through a combination of dif-
ments that are typically dictated fraction and refraction, the diffusion (which
by the class of the LED driver. occurs only on the surface of the substrate) is
extremely efficient (up to 92%) independent
Holographic versus of thickness and provides precise angular
volumetric diffusion beam control.
There are also different approaches Lower-performance diffusers, such as
to tertiary optics that must meet volumetric diffusers, incorporate scat-
application requirements. Tertiary tering elements within the volume of the
optics are available in low- and substrate. These diffusers typically are
high-performance versions. less efficient in the 3070% transmission
The main difference lies in range. The optical properties of volumet-
ric diffusers are very dependent on thick-
FIG. 3. An Elation Lighting ness and provide little or no control of the
architectural wall washer. beam angle of a lamp or fixture.
LEDsmagazine.com
 Philips Fortimo
LED Line Gen 2
Systems
Features and Benets
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1.888.589.3662
Americas@FutureLightingSolutions.com

   

optics | SSL DIFFUSERS

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. Its 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
FIG. 5. A diffuser producing the spot beam on the right eliminates the striations BTDF (Bi-directional Transmittance
evident in the beam on the left. 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,
FIG. 6. Tertiary optic materials on the left and finished products on the right. flexibility, and a cleaner target plane.
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science | UV CURING

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.

W
hen people hear the terms light-
emitting diodes or LEDs, most m Monomer
people think of visible LEDs for o Oligomer
lighting applications. Indeed, LED tech- p Photo-initiator
nology is used increasingly throughout the Ink/coating
world for indoor lighting, outdoor lighting,
Substrate
street lighting, automotive, and signage.
But there are many other industrial appli- o m
cations such as curing (drying) and counter- m p p
feit detection. Ultraviolet (UV) LED technol- o
p o o m o m
ogy for curing is one of the market segments p m p m p p
that has gained worldwide acceptance and o
p o o m o m
continues to grow. Lets examine the state p m m p p
p o
of UV curing technology and consider how Liquids applied: o m
p o
inks, coatings,
well LEDs are fulfilling promises of taking p m
adhesives p
over that space. UV-LED exposure
causes chemical reaction
UV-LED curing refers to a technique that
Liquids harden,
utilizes energy output from the LEDs in the
fnal product is UV cured
UV spectrum to treat inks, coatings, adhe-
sives, and other UV-curable materials. The FIG. 1. UV light instigates a chain reaction resulting in curing of materials such as
energy generated by the UV light triggers a inks or adhesives.
chain reaction resulting in polymerization
of the material, thus hardening or curing the The color of the light emitted or corre- are many benefits driving companies to
material (Fig. 1). For more background on sponding energy of the photon is determined move toward acceptance of UV-LED technol-
UV-LED curing, see UV LEDs ramp up the by the energy gap of the semiconductor mate- ogy such as higher productivity and a more
quiet side of the LED market (links on p. 63). rial. A number of companies that make LEDs environmentally-friendly solution, which
Traditionally, mercury-based UV lamps used for general illumination also make LEDs more and more end customers are demand-
have been utilized for curing, but now more that radiate in the UV spectrum. ing. As manufacturers are developing UV-
energy-efficient and environmentally- LED curing systems, knowing how the key
friendly LED-based UV technology has Advancements in UV-LED curing sub-components work together will help in
proven a superior solution for many applica- It is an accepted fact for many industries creating the optimum system and thereby
tions. LED curing technology uses semicon- that LED lamps provide many advantages reducing the overall environmental impact
ductor-based LEDs to project the UV light including lower energy consumption, lon- of the process and at the same time main-
when an electric current is passed through ger lifetime, improved robustness, smaller taining or improving productivity and prod-
them. When an LED is forward-biased, form factor, and faster on/off switching. uct performance.
electrons are able to recombine with elec- Those advantages are also important in cur-
tron holes within the device, thus releasing ing applications. Application segments
energy in the form of photons. UV-LED curing technology has advanced Curing is a broad market with many appli-
significantly in the past few years and is now cation niches. But lets consider some of the
BILL CORTELYOU is president and CEO of readily available for a variety of applications major application segments:
Phoseon Technology. in printing, coatings, and adhesives. There Printing: The UV curing process has been

LEDsmagazine.com MARCH 2014 59

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, flexographic, 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 flooring 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/cm 2 , 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
60 MARCH 2014
LED 385/395/405 nm LED only
LED Relative
LED 365 nm range intensity
Mercury lamp
355 365 385 395 405 415
Wavelength (nm)
Relative
intensity
Wavelength (nm)
UVC UVB UVA Visible light Infrared
100-280 nm 280-315 nm 315-400 nm 400-700 nm 700-1800 nm
FIG. 2. The spectral energy distribution of UV LEDs is different from that of legacy
mercury lamps that were broadly used in the past.
have UV-LED-curable chemistries along with LED curing lamps were installed on equip-
aggressive technology and product roadmaps. ment at the 2013 show, up from 10 instances
Although the monochromatic nature of during the 2011 show for an 8x increase. Cur-
UV-LED lamps requires special consideration ing uses ranged from pinning to full cure
from the chemists, it has not been a long-termand many of the printers were 100% UV-
impediment as once thought. LED based.
One of the most exciting aspects of utiliz- Attracting the highest ever number of
ing a UV-LED curing process is that it opens entrants in its history, the Label Industry
many new process possibilities with its Global Award for Innovation,
precise electronic control of energy sponsored by Label &
delivery. Many users have tai- Narrow Web, Labels
lored their processes to achieve & Labeling, and Nar-
results unattainable through roWebTech maga-
other means. Today there zines, was jointly won
are many proprietary by Mark Andy and Flint
uses of energy con- Group Narrow Web. Flint
trol across varying Group was honored for its
applications. Ekocure UV-LED ink technol-
ogy, which the judges described as
Recent milestones providing improved cure response,
Consider the milestones reached cost and productivity savings, waste
in 2013. The Labelexpo Europe FIG. 3. An air- reduction, energy savings, and
2013 tradeshow reflected large- cooled UV-LED enhanced safety that will undoubt-
scale UV-LED adoption. The curing system. edly have a significant impact on
event validated the claims of rapid the future of the label industry.
adoption of UV-LED curing. The Mark Andy was recognized for its
show reported record-breaking attendance complementary ProLED ink curing technol-
figures by attracting 31,795 visitors (up 11% ogy, which delivers high production rates and
over 2011) from 158 countries (up from 123 50% energy savings.
in 2011) with nearly 600 exhibitors (up from
550 in 2011). Everywhere they looked, attend- More material formulation suppliers
ees saw UV-LED curing systems being imple- At the advent of UV-LED curing, some ten
mented on machines. To UV LEDs tradi- years ago, very few types of inks, coatings,
tional strength of digital inkjet were added and adhesives were compatible with UV-LED
rotary screen printing, area curing, offset, technology. As Fig. 2 shows, the spectral
and flexographic printing. energy distribution of UV LEDs is quite
Comparing Labelexpo 2013 to Labelexpo different from that of mercury lamps and
2011 proves just how rapidly the industry has indeed is in a much narrower band. That dif-
adopted the technology. More than 80 UV- ference required new material formulations.
LEDsmagazine.com

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
science | UV CURING
for applications such as edge
coating, roller coating, and
digital printing. UV-LED
technology drastically
reduces energy con-
sumption and sig-
nificantly reduces
work-piece surface
temperature. Edge coat-
ing lines utilize UV LEDs to
more efficient in delivering higher FIG. 4. A water- ensure consistent, high-quality
energy to the media, thus driving cooled UV-LED results. Machines can be made
not only increased throughput and curing system. more compact due to small form
process flexibility but also envi- factor; speed can be increased
ronmentally-friendly and energy-efficient due to consistent UV output; and the dif-
solutions. End users are rapidly moving to fuse nature of UV-LED light can be used to
UV-LED curing technology due to the accu- more effectively cure shaped surfaces that
mulation of benefits. Figs. 3 and 4 show air- previously required multiple lamps at var-
and water-cooled UV curing products. ious angles.
The advancements are opening new UV LED is a perfect match for roller coat-
applications. Due to recent advances in ing lines, both for controlled gelling and
high-powered air-cooled products, UV-LED full-cure stations. The benefits include bet-
curing technology now enables the wood ter factory floor utilization due to shorter,
coatings industry to leverage the technology more efficient lines; increased uptime with
 science | UV CURING
FIG. 5. Flat-panel display manufacturing is one of several applications enabled by
UV-LED sources.
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 flat-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
62 MARCH 2014
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 flexibility 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
LEDsmagazine.com

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
science | UV CURING
LED DRIVERS
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-

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.
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
5-YEAR WARRANTY
10-300 WATT MODELS
mers, oligomers, resins, and photo-initia-
480V INPUT
tors exclusively developed for LEDs charac-
teristic UV output. DC INPUT
Regulator issues will also drive the tech- CUSTOM DESIGN &
nology forward. Legislative and non-govern- MODIFICATIONS
mental organizations worldwide continue to
address concerns around products contain- DIMMING OPTIONS
ing mercury. The European Unions 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.

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
US ENGINEERING
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 SUPPORT
life of refrigerated produce after a study based on strawberries that was conducted with the US
EXTENSIVE
Department of Agriculture.
http://bit.ly/MESw3d DISTRIBUTION

LUXeXceL demonstrates its patented manufacturing technology for printable optics SUPPORT
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. AUTEC.COM

http://bit.ly/1eYOngo 805.522.0888

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

LEDsmagazine.com MARCH 2014 63

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design forum | THERMAL SIMULATION
Simulation enables optimum LED
street light heat-sink design
DJORDJE ZIVANOVICand 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.
C
ompanies 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.
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.
LEDsmagazine.com
Outdoor luminaire design mum heat dissipation surface?
BUCK is a company in Belgrade that pro- Where will the hottest air pockets be
duces luminaires for architectural and med- formed?
ical illumination. The company has expanded Optimizing the heat-sink design empiri-
its work to outdoor luminaires, and they took cally would require a lot of time and money.
on a joint project with Panasonic Serbia to The R&D team decided to use software simu-
create a self-cleanable heat sink for outdoor lation and analyses to speed up the develop-
lighting fixtures that would improve on an ment time. The computational fluid dynam-
existing extruded heat sink. Thermal design ics (CFD) software they chose, FloEFD from
is critical in SSL products because high tem- Mentor Graphics, provides guidance and
peratures can reduce an LEDs light output help so that engineers who are not CFD spe-
and cause color shift
effectively shortening the
components 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. FIG. 1. Thermal simulation of the original heat-sink design,
Finding the optimum solu- showing airflow in FloEFD.
tion for thermal problems
can take 80% of the time the development cialists can perform fluid flow, cooling, and
team spends on designing a new product. other analyses as part of their design process
During the design development phase of and within their product design tool.
the street light fixture, the R&D team started
with the question, How can we solve the cool- CFD simulation
ing of LED modules in the most efficient way? The software allows engineers to perform
Based on years of experience in designing heat CFD automatically without the atten-
transfer equipment, the answer was easy: Take tion of a trained specialist. This automa-
the heat away from the LED module, provide tion means that product designers can try
enough surface-to-heat dissipation, and pro- out a succession of ideas on a design with-
vide good airflow. out risking the project deadline, while also
But some questions werent so easy: reducing simulation time compared to tra-
How much airflow is needed to take the ditional CFD tools.
heat away at 55C ambient temperature The CFD software also makes it relatively
from the 140W high-power LED module? easy to conduct what-if tests. FloEFD helps
In what way can we provide the opti- create multiple variations of designs by
MARCH 2014 65
design forum | THERMAL SIMULATION

modifying parametric CAD configurations, preparation within the CATIA environ- accumulate and erode surfaces. This lets
which can then be analyzed without hav- ment. Engineers use a configuration wiz- the engineers visualize where dirt will fall
ing to reapply loads, boundary conditions, ard to prepare the solid model by applying out of the flow and gather on the heat sink,
material properties, and the like. The engi- loads and boundary conditions and finally or preferably be carried out of the heat sink.
meshing the model before The use of thermal simulation software
analyzing it. By design- both significantly shortened the develop-
ing the heat-sink model ment time of the SSL product and provided
in CATIA as a mechani- operational details that would have been
cal model and simulat- difficult to obtain otherwise. The result
ing with FloEFD from the for BUCK was the design of a new heat-sink
thermal standpoint, the model with vertical fins, which features a
thermal properties can be higher airflow for the self-cleaning effect
attached to all the poten- that prevents dirt deposition (Fig. 3).
tial shapes considered for The self-cleaning heat sink has a simi-
the heat sink, and the LED lar mass to the original one, but it doesnt
module that is the source need as much additional work and time on
FIG. 2. With optimization in the thermal simulation of heat. the milling machine. The simpler manufac-
software, the team was able to verify quickly and reliably After the design optimi- turing process resulted in not only cost sav-
whether the dirt deposition on the heat sink could lead to zation of the heat sink, the ings but also significantly reduced main-
malfunction while the luminaire is working. team obtained data on the tenance in the end product, and achieved
number, height, and thick- longer product life.
neer simply compares the results among the ness of the fins that would provide the best
many design options to choose the best pos- possible heat dissipation for the LED mod- Modeling the LEDs
sible design. ules (Fig. 1). As part of the optimization pro- The team also utilized a new FloEFD LED
The simulation software enables product cess, the team also wanted to test the effect module feature that delivered reliable results
designers as well as specialists to acceler- on cooling of dust accumulation over the top effortlessly. The values from the FloEFD simu-
ate key decisions at their workstations as of the heat sink. lations were within 3% of the results obtained
they experiment with design scenarios Dust/dirt deposition reduces the avail- later by measurements on the physical model.
and as they hone in on the best, most effi- able surface area for heat
cient, reliable, and cost-effective design. transfer, creates addi-
This intuitive virtual prototyping process tional thermal resis-
allows designers to optimize a product dur- tance for heat to get to
ing the design stages, with that first phys- the ambient, and reduces
ical prototype often being the design that the amount of airflow that
goes into final manufacturing, delivering can travel between the
the best design at lower cost, and getting it heat-sink fins removing
to market faster than ever before. heat. In the simulation,
Without simulations, the R&D team the team added a com-
would have needed at least 6 to 10 physi- ponent to represent dirt/
cal prototypes, and the team still wouldnt dust placed over the top of
have been able to guarantee they had the the heat sink (Fig. 2).
best solution. Empirical testing would have FIG. 3. Thermal simulation of the new heat-sink design with
cost a minimum of three additional months Self-cleaning design dirt deposition.
of development time and at least 500 in In addition to optimum
prototype costs. By using FloEFD, they cut cooling, the goal of the team included The LED module in FloEFD simulates
thermal simulation and management time designing a self-cleaning heat sink. The an LED component as a compact package
down to one month. desired self-cleaning effect requires high based on either a simple two-resistor model
air velocities relative to natural passive con- or an advanced measurement-derived
Solid modeling vection standards, in order to minimize dirt model. The detailed model includes a
The team performed the series of simula- deposition. The airflow was simulated using unique solution to the challenge of design-
tions in FloEFD based on a parameterized the FloEFD particle study feature. The par- ing SSL and allows thermal and photomet-
CAD model created in CATIA V5, a solid ticle study feature in the simulation soft- ric models of LEDs obtained from testers to
modeling tool. FloEFD V5 is a concurrent ware permits injection of virtual particles be used in FloEFD under constant-current
CFD product, and that allows the model with a material diameter and mass into the operating conditions.
to be immediately available for analysis fluid flow to determine where particles will The model correctly accounts for power

66 MARCH 2014 LEDsmagazine.com

 design forum | THERMAL SIMULATION

that is emitted as light when calculating the radiation). Light

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 reflection, and wavelength
dependency (spectrum properties of the
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- FIG. 4. The final award-winning LED
ded in CATIA to meet the goal of designing industrial luminaire with the self-cleaning
a new heat sink with vertical fins, a higher heat sink.
airflow, and a self-cleaning effect that pre-
vents dirt deposition. By using the ther- LED-based luminaire called Tangram (Fig.
mal simulation software, they significantly 4) also won a Good Design Award from the
shortened the development time and were Chicago Athenaeum Museum of Architec-
provided with details they couldnt other- ture and Design.
wise see to analyze their prototype. They
also were able to obtain the experience that ACKNOWLEDGMENT
contributes to faster and better solutions of The authors wish to acknowledge the support
future problems. The new heat-sink design received in writing this article from Mircea
enabled the company to reduce the cost of Slanina, the responsible account manager
manufacturing and maintenance as well as working with TRIAS microelectronics SRL, a
extend the product life. The companys final Mentor Graphics distributor.

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40132.3 LEDs
LED 01-14

LEDsmagazine.com MARCH 2014 67

last word

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 UKs
WEEE-compliant recycling-service-provider Recolight.

L
EDs 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-collection helps to
establish an LED retrofit
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.

68 MARCH 2014 LEDsmagazine.com

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