Manufacturing
   
 

In 2014 the global LED lighting market will grow by 7 per cent, and continue to grow to an estimated market size of 16 Billion Dollars by 2018 (Yole 2013). The demand for LEDs and other electronic components will be especially driven by the growing demand for retrofit LED lamps over the next years. To better understand the advantages and drawbacks of different LED luminaire designs, retrofit LED lamps were analyzed. Long term measurements of light characteristics such as brightness or colour were made on more than 50 models from 26 different manufacturers.

 
  Figure 1: Test installation for long term investigation
  Through analyzing their design and assembly following results were derived:
  • lamp design and assembly quality ranges from good to poor
  • thermal management can be improved in many cases
  • lamps have a low material value (for recyclers)
  • their design is optimized for mass production
  • the variety and complexity of materials used (plastics, ceramics, aluminium, glass including different glues)

The analyses showed that by using current thermal management technologies 80 % of the technical lifetime of the LEDs (up to 100,000 hours) can be reached. Nevertheless low quality assembling can result in extreme accelerated aging. The type of LED used has minor influence on lifetime. The results of the retrofit investigations will be considered when designing the four CycLED demonstrator products, including strong quality control to achieve maximum lifetime for the LEDs.

 
        Figure 2:  Long term measurement of luminous flux over time on 50 different retrofits
 

CycLED will develop four lighting products demonstrating eco-innovative solutions to resource efficiency:

  • Demonstrator 1 (Braun Lighting Solutions) for street lighting, with a focus on minimising service requirements and ease of maintenance through design for repair and upgrade
  • Demonstrator 2 (ETAP) for commercial lighting in harsh environments (e.g. aggressive gases in car park houses) with a focus on extended service life
  • Demonstrator 3 (Ona) for decorative lighting with a focus on designing an optimal ‘green’ product (including use of recycled materials, modular design, design for recycling and closed loop re-use)
  • Demonstrator 4 (Riva lighting) for industrial lighting with a focus on servitisation (selling lighting performance and service) instead of luminaire products (including design for longevity, upgrade and repair)

 
All technical parameters of the demonstrators are specified and now the first demonstrators are planned and under construction, where eco-innovative designs will be developed. Deadline for all four demonstrators is April 2015.

 

For more information please contact: Adrian Mahlkow (mahlkow at out-ev dot de)