LED BULB MANUFACTURING UNIT

[EIRI/EDPR/4046] J.C.: 2179XL

INTRODUCTION

A light emitting diode (LED) is a device which converts electrical energy to light
energy. LEDs are preferred light sources for short distance (local area) optical fiber
network because they: are inexpensive, robust and have long life (the long life of
an LED is primarily due to its being a cold device, i.e. its operating temperature
being much lower than that of, say, an incandescent lamp),can be modulated (i.e.
switched on and off) at high speeds (this property of an LED is also due to its
being a cold device as it does not have to overcome thermal inertia),couple enough
output power over a small area to couple to fibers (though the output spectrum is
wider than other sources such as laser diodes).

A light-emitting diode (LED) is a two-lead semiconductor light source. It is a p–n

junction diode, which emits light when activated.[4] When a suitable voltage is
applied to the leads, electrons are able to recombine with electron holes within the
device, releasing energy in the form of photons. This effect is called
electroluminescence, and the color of the light (corresponding to the energy of the
photon) is determined by the energy band gap of the semiconductor.

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Types of LED

(1) Miniature

Photo of miniature surface mount LEDs in most common sizes. They can be much
smaller than a traditional 5 mm lamp type LED which is shown on the upper left
corner.

Very small (1.6x1.6x0.35 mm) red, green, and blue surface mount miniature LED
package with gold wire bonding details. These are mostly single-die LEDs used as
indicators, and they come in various sizes from 2 mm to 8 mm, through-hole and
surface mount packages. They usually do not use a separate heat sink.[116]
Typical current ratings ranges from around 1 mA to above 20 mA. The small size
sets a natural upper boundary on power consumption due to heat caused by the
high current density and need for a heat sink. Package shapes include round,
with a domed or flat top, rectangular with a flat top (as used in bar-graph
displays), and triangular or square with a flat top. The encapsulation may also be
cleor tinted to improve contrast and viewing angle. Researchers at the University
of Washington have invented the thinnest LED. It is made of two-dimensional (2-
D) flexible materials. It is 3 atoms thick, which is 10 to 20 times thinner than
three-dimensional (3-D) LEDs and is also 10,000 times smaller than the thickness
of a human hair. These 2-D LEDs are going to make it possible to create smaller,
more energy-efficient lighting, optical communication and nano lasers.

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There are three main categories of miniature single die LEDs:

• Low-current: typically rated for 2 mA at around 2 V (approximately 4 mW

consumption).

• Standard: 20 mA LEDs (ranging from approximately 40 mW to 90 mW) at

around:

 1.9 to 2.1 V for red, orange and yellow,

 3.0 to 3.4 V for green and blue,
 2.9 to 4.2 V for violet, pink, purple and white.

• Ultra-high-output: 20 mA at approximately 2 V or 4–5 V, designed for viewing in

direct sunlight.

5 V and 12 V LEDs are ordinary miniature LEDs that incorporate a suitable series
resistor for direct connection to a 5 V or 12 V supply.

(2) Mid-range

Medium-power LEDs are often through-hole-mounted and mostly utilized when an

output of just tens of lumens are needed. They sometimes have the diode mounted
to four leads (two cathode leads, two anode leads) for better heat conduction and
carry an integrated lens. An example of this is the Super flux package, from
Philips Lumileds. These LEDs are most commonly used in light panels, emergency
lighting, and automotive tail-lights. Due to the larger amount of metal in the LED,
they are able to handle higher currents (around 100 mA). The higher current
allows for the higher light output required for tail-lights and emergency lighting

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(3) High-power

High-power light-emitting diodes attached to an LED star base (Luxeon, Lumileds)

See also: Solid-state lighting, LED lamp and Thermal management of high-power
LEDs

High-power LEDs (HPLEDs) or high-output LEDs (HO-LEDs) can be driven at

currents from hundreds of mA to more than an ampere, compared with the tens of
mA for other LEDs. Some can emit over a thousand lumens. LED power densities
up to 300 W/cm2 have been achieved.[120] Since overheating is destructive, the
HPLEDs must be mounted on a heat sink to allow for heat dissipation. If the heat
from a HPLED is not removed, the device will fail in seconds. One HPLED can
often replace an incandescent bulb in a flashlight, or be set in an array to form a
powerful LED lamp.

Some well-known HPLEDs in this category are the Nichia 19 series, Lumileds
Rebel Led, Osram Opto Semiconductors Golden Dragon, and Cree X-lamp. As of
September 2009, some HPLEDs manufactured by Cree now exceed 105 lm/W(e.g.
the XLamp XP-G LED chip emitting Cool White light) and are being sold in lamps
intended to replace incandescent, halogen, and even fluorescent lights, as LEDs
grow more cost competitive.

Evidence of Haitz's law which predicts an exponential rise in light output and
efficacy of LEDs over time. For example, the CREE XP-G series LED achieved 105
lm/W in 2009 while Nichia released the 19 series with a typical efficacy of 140
lm/W in 2010.

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(4) AC driven LED

LEDs have been developed by Seoul Semiconductor that can operate on AC power
without the need for a DC converter. For each half-cycle, part of the LED emits
light and part is dark, and this is reversed during the next half-cycle. The efficacy
of this type of HPLED is typically 40 lm/WA large number of LED elements in
series may be able to operate directly from line voltage. In 2009, Seoul
Semiconductor released a high DC voltage LED, named as 'Acrich MJT', capable of
being driven from AC power with a simple controlling circuit. The low-power
dissipation of these LEDs affords them more flexibility than the original AC LED
design.

Advantages

• Efficiency: LEDs emit more lumens per watt than incandescent light bulbs.
The efficiency of LED lighting fixtures is not affected by shape and size,
unlike fluorescent light bulbs or tubes.

• Color: LEDs can emit light of an intended color without using any color
filters as traditional lighting methods need. This is more efficient and can
lower initial costs.

• Size: LEDs can be very small (smaller than 2 mm2) and are easily attached
to printed circuit boards.

• On/Off time: LEDs light up very quickly. A typical red indicator LED will
achieve full brightness in under a microsecond.[134] LEDs used in
communications devices can have even faster response times.

• Cycling: LEDs are ideal for uses subject to frequent on-off cycling, unlike
incandescent and fluorescent lamps that fail faster when cycled often, or
high-intensity discharge lamps (HID lamps) that require a long time before
restarting.

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 • Dimming: LEDs can very easily be dimmed either by pulse-width
modulation or lowering the forward current. This pulse-width modulation is
why LED lights, particularly headlights on cars, when viewed on camera or
by some people, appear to be flashing or flickering. This is a type of
stroboscopic effect.

• Cool light: In contrast to most light sources, LEDs radiate very little heat in
the form of IR that can cause damage to sensitive objects or fabrics. Wasted
energy is dispersed as heat through the base of the LED.

• Slow failure: LEDs mostly fail by dimming over time, rather than the abrupt
failure of incandescent bulbs.

• Lifetime: LEDs can have a relatively long useful life. One report estimates
35,000 to 50,000 hours of useful life, though time to complete failure may
be longer. Fluorescent tubes typically are rated at about 10,000 to 15,000
hours, depending partly on the conditions of use, and incandescent light
bulbs at 1,000 to 2,000 hours. Several DOE demonstrations have shown
that reduced maintenance costs from this extended lifetime, rather than
energy savings, is the primary factor in determining the payback period for
an LED product.

• Shock resistance: LEDs, being solid-state components, are difficult to

damage with external shock, unlike fluorescent and incandescent bulbs,
which are fragile.

• Focus: The solid package of the LED can be designed to focus its light.
Incandescent and fluorescent sources often require an external reflector to
collect light and direct it in a usable manner. For larger LED packages total
internal reflection (TIR) lenses are often used to the same effect. However,
when large quantities of light are needed many light sources are usually
deployed, which are difficult to focus or collimate towards the same target.

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 CONTENTS

INTRODUCTION
TYPES OF LED
(1) MINIATURE
THERE ARE THREE MAIN CATEGORIES OF MINIATURE SINGLE DIE LEDS:
(2) MID-RANGE
(3) HIGH-POWER
(4) AC DRIVEN LED
ADVANTAGES
DISADVANTAGES
TECHNOLOGY OVERVIEW OF LED BULB
LED LAMPS BULB
WHITE LIGHT LEDS
COLOR CHANGING LED LIGHTING
LED DRIVERS
THERMAL MANAGEMENT
EFFICIENCY DROOP
HOUSEHOLD LED LAMP
LAMP SIZES AND BASES
HOW LEDS PRODUCE LIGHT
WHITE LIGHT LED TECHNOLOGY FOR GENERAL ILLUMINATION
THE MANUFACTURING OF WHITE LIGHT LEDS
MANUFACTURING PHASES OF PACKAGED WHITE LIGHT LED ASSEMBLY
SUBSTRATE PRODUCTION
1. PREPARATION OF THE SEMI-CONDUCTOR WAFERS
2. ADDING EPITAXIAL LAYERS
LED DIE FABRICATION PROCESS
PACKAGING THE LED ASSEMBLY
FINISHED PACKAGED LED THE PHILIPS LUXEON REBEL: AN ILLUSTRATION
RAW MATERIALS
VARIOUS MATERIALS USED FOR MULTI-COLOUR LEDS
LED LAMP CHARACTERISTICS
TREND FOR LED RETROFIT LAMP CHARACTERISTICS IN INDIA
USES AND APPLICATION
USES
(1) POWER SOURCES
(2) ELECTRICAL POLARITY
(3) SAFETY AND HEALTH
APPLICATIONS

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LED USES FALL INTO FOUR MAJOR CATEGORIES:
B.I.S. SPECIFICATIONS
MARKET OVERVIEW OF LED BULBS
INDIAN MARKET SIZE
MARKET GROWTH
THE MAJOR DEMAND-GENERATING APPLICATION AREAS ARE:
MARKET STUDY
GOVERNMENT FACILITATING WIDE SCALE IMPLEMENTATION
OF LED LIGHTING
CURRENT OPPORTUNITIES
DRAFT SPECIFICATIONS FOR LED SELF BALLASTED LAMPS
DRAFT SPECIFICATIONS FOR LED DOWNLIGHTERS
DRAFT SPECIFICATIONS FOR LED SECONDARY ROAD STREET LIGHTS
LED PROFESSIONAL PRODUCTS (LUMINAIRES)
LED REPLACEMENT AND RETROFIT LAMPS
THE PROMISE OF LEDS
CHARACTERISTICS OF LED RETROFIT LAMP SOLUTIONS
MANUFACTURERS/SUPPLIERS OF LED BULB
METHOD OF MANUFACTURING LED BULBS
MAUFACTURING PROCESS OF LED BULBS HOUSING
PROCESS FLOW DIAGRAM
PROCESS FLOW CHART
MANUFACTURING PROCESS IN DETAILS
(A) MANUFACTURING OF LED
SUBSTRATE MANUFACTURING
INORGANIC SEMICONDUCTOR MANUFACTURING
EPITAXIAL PROCESS
PHOSPHOR MANUFACTURING
LIGHT-EMITTING DIODE ASSEMBLY AND PACKAGING
LED MOUNTING ON PCB
1: THROUGH HOLE COMPONENT MOUNTING
2: SMD PICK AND PLACE MACHINE
3: SOLDER PROCESS
4: REFLOW SOLDERING PROCESS
5: REPAIR AND REWORK
LED BULB ASSEMBLY PROCESS
MANUFACTURING MACHINES
MACHINES FOR LED MANUFACTURING
MACHINES FOR LED ASSEMBLY
DRILL MACHINE: FOR VARIOUS DRILLING JOBS
TESTING EQUIPMENT FOR LED
ELECTRONIC COMPONENT TESTING EQUIPMENT
EQUIPMENT FOR ASSEMBLY
ENVIRONMENTAL ASSES REPORT ON LED TUBE AND BULB

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FIGURE 4-1 LED PACKAGE
FIGURE 4-2. LED LAMP
LIFE CYCLE FLOWS AND PROCESSES
OVERVIEW
FIGURE 4-3. MATERIALS FLOW FOR LIGHT-EMITTING DIODE LAMP
RAW MATERIALS EXTRACTION AND PROCESSING
LED CHIP
CRYSTALS AND SUBSTRATES
TABLE MATERIALS BY COLOR PRODUCED
LED PACKAGE (HOUSING)
THE TYPICAL LED PACKAGE CONTAINS:
LED LAMP
MATERIALS INVENTORY FOR LED LAMP FROM THE OSRAM STUDY
LED PACKAGE (HOUSING)
LAMP
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF PLANT AND MACHINERY FOR LED TUBE
AND BULB [IMPORTED]
SUPPLIERS OF RAW MATERIAL FOR LED TUBE AND BULB

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 60,000 Bulbs/Day

Land & Building (1500 sq.mt.) Rs. 2.31 Cr
Plant & Machinery Rs. 89 Lac
Working Capital for 1 Month Rs. 3.39 Cr
Total Capital Investment Rs. 6.76 Cr
Rate of Return 48%
Break Even Point 38%

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