The Race to the Underside: LED Bulbs And DFM
The dropping price of LED bulbs is accelerating. We examine a number of manufacturers to see how they're approaching design and lower value manufacturing. You've got probably seen LED bulbs situated next to the incandescent and compact fluorescent (CFL) bulbs at your local hardware store. I spend manner an excessive amount of time in these aisles. That is capitalism at its most interesting! I discover the battle of new tech, good manufacturing, EcoLight solutions and big demand intriguing. I've switched almost all the lights in our house over to LED partly due to the (small) energy savings, however largely because I am lazy: A 22-12 months lifetime means I do not must climb a ladder for a while. After i bought my LED bulbs just a few years in the past they had been round $15 a pop. As with most all tech, I've watch the value drop over time. In this case, LED bulbs in my local House Depot (Philips 60W) are hovering round $10.
On a recent go to to the lighting aisle I used to be taken off guard when a pack of two 60W bulbs by Philips had been selling for $5 ($2.50 every!). This isn't just a drop in value, EcoLight solutions that is an all out value war between some heavy hitters. Confusing me was the truth that right subsequent to these 60W bulbs for $2.50 were 60W bulbs for $10 from the same producer. Upon nearer inspection I observed one thing odd. These lower value LEDs had a display life of 10 years versus 22. Ok, in order that they shaved some cost by shortening the life span of the bulb. Neat marketing trick but the engineer in me wished to understand how. Nothing too crazy. Each bulb claimed to be 800 lumen at varied power consumption ranges (8.5W to 9.5W). And that i solely seen this now however the cheap bulbs are non-dimmable. Arduous to see within the above image however the bulb in the center (low cost Philips) is slightly shorter than the dearer Philips bulb.
The TCP is about a centimeter taller. This has little effect on lighting but millimeters of materials will begin to matter. I did a fast initial check to see how the bulbs performed. 13.2W). Maybe the precise LEDs eat 9.5W and EcoLight the ballast (the factor converting AC to DC) consumes the rest. This would be a brilliant-sneaky advertising and marketing ploy, as I assumed the rating on the surface of the packaging was the overall power consumption of the bulb. All three bulbs had opaque plastic higher bodies. The expensive Philips bulb got here apart with some strong twisting. Beneath was a neat plastic diffuser. Underneath the diffuser was a mixture of small and large LEDs. Not what I might have anticipated - 14 large LEDs, 6 small. A, EcoLight solutions as well because the date code: EcoLight solutions 2014-10-14, a delta of 7 months from when i purchased the bulb. The date is probably in relation to design version and never manufacture date.
With fairly a little bit of prying pressure, the metal LED PCB comes off the steel base heatsink. This was to be expected; there was good thermal grease sandwiched between the PCB and EcoLight smart bulbs the heatsink. Some further prying and we are able to see the ballast beneath. I obtained a bit forceful with a hacksaw so ignore the hack marks for EcoLight the second. The metal base is threaded onto the plastic base after which spot crimped to the plastic (you'll be able to see the multiple dots or dimples around the metal base). This is the primary clue that Philips is engaged on simplifying the manufacturing course of. Furthermore, the two uncovered wires in the image should not soldered to the base, EcoLight solutions they are compressed to it, EcoLight solutions moreover simplifying the meeting process. The ballast! A lot of caps, EcoLight solutions an inline fuse, transformer, inductor, and EcoLight products a few transistors. C1, C2 and C3 are metalized polyester movie capacitors. Here is the rear aspect of the ballast.