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Fluorescent LED lamp Aluminum mcpcb aplication

Fluorescent LED lamp Aluminum mcpcb aplication
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Fluorescent LED lamp Aluminum mcpcb aplication

  • Fluorescent LED lamp Aluminum mcpcb aplication
    We are one of the Biggest and reliable LED Raw Material supplier and traders in North India. We supply highly advanced range of LED Bulbs and raw material in multiple colors, size, quality and range. We have since been committed in manufacturing, supplying, wholesaling, trading and retailing a huge gamut of supreme quality LED BULB , LED RAW MATERIAL ,CFL Raw Material, CFL BULB since 2000. We have a good unit of manufacturing of LED bulb and supplying of led bulb raw material. We are providing high quality LED bulb material in low prices and we are giving to chance to our customer to make good business deal and enhances business at high level

    We provide you the best range of LED Raw Materials such as Raw Material of LED Lamps, LED Bulb Raw Material, LED BULB COMPLETE KIT (FULL ALUMINUM), LED BULB COMPLETE KIT (PBT), LED Bulbs Housing, LED Bulbs Raw Material and many more items with effective & timely delivery.

    With the support of our talented professionals, we are passionately engaged in offering high quality LED Bulb Raw Material. Using superior quality basic material and pioneered methodology, our provided material is manufactured under the vigilance of our skilful engineers. We follows the all industry standards.

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    Power: 5 Watt with Led driver
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    Who Wins...Fluorescent Bulbs vs LED Bulbs

    For the last 3 years we have been touting the benefits of T8 lighting. T8 has been one of the cheapest options out there for high bay and office lighting retrofits. LED technology has just been too expensive to purchase and installation was a significant cost as well.

    Why LED now?

    We now sell LED, because we have seen how the T8 bulbs that we warranted for 3 years are failing at 2.5 years. They were supposed to last 40,000 hours, well beyond 3 years, but we had several fail at 2.5 years.

    We recently went back to warranty some bulbs that had burned out, which were minimal but still a nuisance. We just happened to be 6 months past the warranty date. But when my installer got back and said the entire place needed a re-lamp, I about fell off my chair. How could that be?

    Now I know why they are warranted for only 2 years!

    We had already been getting more involved with LED because, as we have noted in other articles, LED technology has really come down in price and there are a lot more options.

    Plus you just cannot beat the lifetime of the LED fixtures, no matter how you compare to T8. We are just in the process of opening our NEW, ONLINE Energy Efficient Lighting Store (www.hoveyledlights.com). ALL of our lighting is energy efficient, or we just won't carry it. By the way, pardon the mess if you happen to go there, we are still "stocking" the shelves!

    One of the products we have decided to carry is a LED Replacement Bulb (4' tube) that replaces existing T8 bulbs in existing T8 fluorscent fixtures. It's a direct replacement meaning you don't have to changeout the ballast (as long as it is an instant start ballast) or provide an additional power source!

    The Hovey LED Replacement Bulbs are:

    LED Strips MCPCB

    The LED revolution is on! LED technology, now over 50 years in the making, enables the “Digitization of Light”. This “Analog-to-Digital Transformation” of light sources, from traditional light sources such as incandescent, fluorescent and HID, to LED, enables a whole new range of applications and markets, from Displays, to Automotive and General Lighting, and emerging markets such as Indoor Vertical Farming and Horticulture, IOT and Visible Light Communications. Our ability to rapidly engineer applications-specific new product designs, coupled with appropriate LED light sources and driver and control electronics, is resulting in rapid adoption of this platform.

    The LED General Lighting segment, in particular, is growing at the fastest rate, with unit volumes of LED retrofit lamps, luminaires and tubes forecast to grow by 50% in 2016, over 2015. This is driven by rapid technological advances, simultaneous cost reductions and scale of manufacturing in LED package technologies as well as systems integration technologies. The key issues that need to be addressed by the LED lighting supply chain include:

    Efficiency, Brightness and Light Quality Improvement (Lumens per Watt)
    Higher efficiency of electrical power to light and lumen output per package reduces energy consumption.
    High heat dissipation
    Good light extraction and directionality
    Reliability and Lifetime Improvement(Lumen Maintenance over Life)
    Reliability of the package and the system determines lifetime of the package and system, and lowers maintenance costs.
    Vibration and high temperature thermal cycling performance
    Cost/Lumen Over the Lifetime($/Lumen and Lumens/$)
    Increased efficiency and brightness, and increased reliability and lifetime reduce the cost per lumen over life.
    New Form Factors
    Greater Integration and Design Freedom
    Role of Interconnects in LED Lighting and Where High Reliability Interconnects Fit

    One important class of applications in the General Lighting segment is high power outdoor lighting such as street lighting. Customers such as municipalities and building owners expect very high reliability of such LED based street lights, since major value propositions include energy savings as well as lumen maintenance over a long lifetime. For such applications, a B50, L70 lifetime of 35,000 hours is needed. For these high reliability and lifetime requirements, it is critical to have excellent assembly interconnect reliability (i.e. LED Package to Insulated Metal Substrate attach).

    The role of interconnects in LED assembly is fundamentally to:

    Before building a superior product we need to clearly define what we want to improve and from what base. As straight forward as it might sound, many do not know where a fluorescent lamp stands in this aspect and hastily jump on the "upgrade with LED" band-wagon simply because of word of mouth about how good, green and lost lasting the new technology is.

    In reality, a switch from fluorescent to LED can be either an upgrade, an downgrade or simply make no difference at all.

    According to our experience, DOE tests and other literature, the performance of the most popular form of fluorescent tube, the T8, is:

    * while in the manufacturer datasheets the luminous flux of the bare lamp is specified, that value is seldom reached in an actual installation. Two important factors have a negative impact: ballast factor and the light loss from converting a 360 degree lamp in a 180 degree (or less) lighting fixture. From an average of datasheet values, a 0.87 ballast factor correction and a 17% further lumen loss was applied.

    Resulting that a LED T8 replacement has to exceed the following performance targets:

    Minimum Lumens target explained:

    Because of the faster depreciation of the the luminous output of LED compared to fluorescent, over the course of its useful lifetime, LED linear lamps should have 20% more lumens.

    LEDs are considered at end of life when they have lost 30% of the initial brightness. In contrast fluorescent lamps loose on average 6% of their light output until their end of life, at which point they fail and do not emit light at all.

    Below: a sample lifetime of an 50.000 hours LED compared with other lighting technologies. Minimum Energy Efficiency Explained:

    "a 50% increase in energy efficiency" or alternatively "a 50% cut in energy costs" is relevant from an economic and environmental point of view and a convincing argument for factors of decision in the business sector.

    Lifetime requirement explained:

    LED lamps are complex products with a higher manufacturing cost and environmental foot print of their production. Compared with a fluorescent linear lamp that has an average life of 25.000 hours, LED linear lamps should have minimum twice that.

    Step 2: Choose between the "Henry Ford" and the "Apple" approach to manufacturing

    Linear LED lamps can replace T8 or T5 fluorescent lamps, but in order to be used as economical substitutes for extremely efficient fluorescent lamps operating round the clock in offices and industrial buildings they have to meet high requirements. As yet there are no uniform standards for defining replacement lamps in this sector. In the following, you will find information about design and technology to create LED retrofit tubes. Important characteristics that have to be considered are total luminous flux, power consumption, system efficacy and the number of LEDs.

    There are three well-known types of tubes: T5 tubes with a diameter of 5/8” or 1.6 cm, T8 tubes with a diameter of 1” or 2.54 cm and the outdated T12 tubes with no LED replacement until now. T5 and T8 tubes feature three different lengths with different lumen packages. At a length of 600 mm the brightness is between 600 and 1000 lumens (lm), at 1200 mm it varies between 1600 and 2500 lm and the longest version of 1500 mm features 2200 to 2500 lm. At the same time, the lamp efficacy ranges between 80 lm/W and 130 lm/W. The common correlated color temperature (CCT) of the tubes is 4,000, 5,000 and 6,500 Kelvin (K).

    We provide you the best range of LED Raw Materials such as Raw Material of LED Lamps, LED Bulb Raw Material, LED BULB COMPLETE KIT (FULL ALUMINUM), LED BULB COMPLETE KIT (PBT), LED Bulbs Housing, LED Bulbs Raw Material and many more items with effective & timely delivery.

    With the support of our talented professionals, we are passionately engaged in offering high quality LED Bulb Raw Material. Using superior quality basic material and pioneered methodology, our provided material is manufactured under the vigilance of our skilful engineers. We follows the all industry standards.

    Supplier of LED Housing offered by Bhagwati Enterprises. Our organization is among the trusted names in the industry for supplying and trading LED Housing Cover. Housing is very much important and required equipments for all the kinds of electrical appliances which contains electrical circuits and printed circuit boards. These compact fluorescent lamp housing is specially designed and manufactured for the purpose of covering the LEDs circuit and electrical board parts in most efficient and reliable manner. These compact fluorescent lamp housing prevents the LEDs circuits and connections from getting dust and damage. These lamp housings are manufactured using top most quality materials which makes it strong and durable.


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    As demand for LED (light emitting diode) luminaries continues to grow, new thermal management technologies are allowing manufacturers to produce LEDs that have higher light output and longer lifespan. LEDs offer many advantages including low energy consumption, long service life (bulbs can last up to 40,000 hours or more), and environmental safety (they contain no mercury). The disadvantages of LEDs, such as higher prices than incandescent or fluorescent lighting, will dissipate as new manufacturing techniques make LEDs less expensive to produce and better able to handle heat fluctuations.

    Thermal management is one of the most important aspects of successful LED systems design, according to the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy. LEDs convert only 20- to 30-percent of their electric power into visible light; the remainder is converted to heat that must be conducted from the LED die to the underlying circuit board and heat sinks. Excess heat can reduce LED light output and shorten lifespan. Therefore, managing thermal output to dissipate heat is crucial to maximizing the LED’s performance potential.

    A Thermal Substrate Alternative
    Currently, for high power/high brightness applications, the LED package or module is soldered to a metal-core printed circuit board (MCPCB), thermally enhanced PCB or a ceramic substrate, which is then bonded to a heat sink. Although this configuration is used widely in the LED industry, it does not offer the best method for managing heat conductivity and can be expensive to produce.

    MCPCBs and thermally enhanced PCBs offer good thermal performance but have limited design flexibility and can become expensive when high thermal performance is required due to additional costs for machining thermal vias and the high cost of expensive thermally conductive dielectric materials. Ceramic substrates are made from lower thermally conductive, but cheaper ceramics, such as alumina, or higher thermally conductive but very expensive ceramics like aluminum nitride. Overall, ceramic substrates are relatively more expensive than MCPCBs and thermally enhanced PCB substrates.

    As an alternative to the substrates discussed above, LED manufacturers are testing the concept of building circuits directly on aluminum substrates, which offer excellent thermal conductivity. Although the LED industry is interested in using aluminum due to its advantages, LED circuits built on aluminum require an insulation layer on the substrate. Now, advances in thick-film technology are allowing the LED industry to reap the benefits of using aluminum substrates.

    IAMS, an Insulated Aluminum Material Systems developed by Heraeus Materials Technology, a supplier of products for thermal management applications, is a low-temperature firing (less than 600°C), thick-film insulating system that can be printed and fired on aluminum substrates. The IAMS material set consists of dielectric pastes, conductors, solder masks, and resistors. All the materials are compatible with 3000, 4000, 5000 and 6000 series aluminum substrates.

    IAMS Advantages
    “IAMS is designed as an insulation system for aluminum substrates,” said Mitsuru Kondo, Global LED Project Manager for the Thick Film Materials Division of Heraeus. “Aluminum cannot handle temperature higher than 660°C, and standard thick-film products are ceramic-based and must be fired at very high temperatures of 800°C to 900°C.

    “Because the IAMS pastes can be fired at less than 600°C, the system is compatible with aluminum processing conditions,” Kondo explained. “Also, IAMS’ unique glass system minimizes bowing on aluminum while providing high dielectric breakdown strength and excellent thermal conductivity.”

    Most thick-film pastes have a CTE (Coefficient of Thermal Expansion) adjusted for use on high- temperature, low-CTE ceramic substrates. However, if you are using aluminum substrates, which have a very high CTE, and a paste designed for ceramics, the substrate will “bow” due to the differences in CTE. The CTE on IAMS is designed to match the CTE of the aluminum, minimizing any bowing.

    Making modifications to the LED package design is simple with IAMS. “Thick-film technology allows the LED circuit design to be screen printed directly onto the aluminum substrate,” noted Kondo. “The screen pattern can be easily changed to accommodate circuit design changes by simply changing the screen and reprinting.” This flexibility can be advantageous during prototyping and design stages.

    In addition, because the printing process used to deposit the IAMS pastes is an additive process with selective deposition capability, costs are low. The insulating pastes are deposited only where the conductive circuit is located and, with the proper design, thermal vias are easily connected directly to the high thermal conductivity aluminum. There is minimal material waste during the circuit manufacturing compared to etched MCPCBs and thermally enhanced PCBs where sheets of copper are chemically etched to create the circuit. With the IAMS system, the conductor paste is deposited only where the circuit needs to be formed.

    IAMS technology also allows the customer to use only one insulating paste. While other thick-film technologies require two different types of glass pastes for each insulation layer, only one paste is needed when using IAMS. Finally, all IAMS pastes meet RoHS requirements.

    A Proven Technology
    Crucial to the performance of LEDs is effective heat dissipation; keeping the LED’s temperature lower helps to increase brightness and life span. To prove that IAMS could provide the thermal management properties that LED manufacturers required, Heraeus sought independent testing. Heraeus asked the VTT Technical Research Center in Oulu, Finland to perform a comparison study of MCPCBs vs. IAMS.

    “We compared the thermal characteristics of LED modules using MCPCBs and IAMS,” said Aila Sitomaniemi, a Research Scientist at VTT. “We tested 10 modules containing high-power LEDs soldered on each board. Each board was placed inside a thermostat chamber that kept the board bottoms at a contact temperature of 25°C to ensure each board received efficient and equal cooling.”

    We are established supplier of a wide array of LED Baser of LEDLight, Raw Material, LED Base Material and Compact Fluorescent Lamp Bulbs offered by Bhagwati Enterprises. Our organization is reckoned as reputed supplier of a remarkable spectrum of LED Lights and allied LED Materials including LED Plastic Cabinet. We produce an exhaustive array of these cabinets by using the finest grades of raw materials in our state of the art manufacturing facilities. Our stringent norms of quality are in total agreement with the laid down standards of the industry and we ensure flawless processes right from the stage of raw material procurement till the final dispatch. Our clients can avail these at economical rates.

    The general structure of LED tubes consists of LED, PCB, heat sink, diffuser cover, socket and LED driver. The diffuser cover increases the viewing angle and reduces the glaring effect. To get the number of LEDs required for the retrofit tube, you can also use available online tools from Osram. There are two types of housing for the T8 tube: LED placed in the middle or at the lower side of the tube. The radius of the tube or the distance between LED and diffuser will determine the LED pitch that is very important for good luminance homogeneity: the higher the distance, the better the homogeneity. With the following formula it can be determined:
    LED pitch = Radius of the tube (LED distance to the diffuser)/1.5

    With the interior and the exterior version there are two types of LED driver or converter. The important selection of the driver determines the LED configurations, serial and parallel. The driver can be placed at the end of the tube or, if there is little space, it can be inserted between the aluminum heatsink and the diffuser. For this type of retrofit tube, the LED configuration is 20 in series of two strings (20Sx2P). As the PCB surface affects the total output brightness it is recommended to use PCBs with a high reflectivity index of more than 95%. Another possibility is to use PET tapes covering a reflectivity index of 98.5%. For even better heat dissipation thermal paste or thermal tape can be applied between LED board and the aluminum heatsink.

    In the following, you find the measurement results and the total cost for an exemplary complete tube.

    In the 1920s, Henry Ford envisioned that total control over the supply chain behind his Ford Motor company is the way forward. For this purpose he purchased iron mines and coal mines to supply the material for his steel mills, rubber plantations for his tire factories and even a railroad company to transport his cars.

    Today Apple builds the Iphones, Ipads entirely from parts produced by someone else (Arm, Samsung and so on) in a factory that it does not own, only visits. That factory is in China, of the company Foxcom.

    In other words, the LED linear lamp can be made from a majority of parts built in house or outsourced.

    It is our opinion that using outsourced parts is the recommended course of action. Further more, for this particular product these parts should be almost entirely off the shelf versions, not custom build. A LED tube is about function and results and not looks.

    Convey power and information efficiently and reliably over the rated life.
    Get the heat out faster and reliably over the rated life.
    Enable more light output, consistently, for longer time for the same package and system footprint.
    New super-high and ultra-high power LED package designs provide high lumen density that can enable significant system cost reductions through fewer LEDs, smaller PCBs, and smallerheat sink size requirements. This, however, puts significant performance demands on the interconnects (solder joints in particular), due to the nature of the materials stack in the assembly, and the high operating temperature inherent in such systems.

    In the case of a super-high or ultra-high power LED assembly on aluminum MCPCB, the ΔCTE between the LED and the MCPCB is 18-20, which is quite high, as shown schematically in Figure 1. During thermal cycling experienced by the LED assembly in applications such as outdoor lighting or automotive, the high ΔCTE causes significant strain energy build-up in the solder joint between the LED submount and the MCPCB, during the thermal cycling experienced in use. This is shown schematically in Figure 2. This strain energy buildup causes micro-cracking, and eventually, failure of the joint.

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    LED PCB -Metal Core Printed Circuit Board
    We take pleasure to introduce ourselves as the renowned organization that is engaged in offering excellently designed LED Strips MCPCB. Manufactured using high grade raw material and cutting-edge technology, these Strips MCPCB are highly accepted by our customers. Further, our range is thoroughly tested against various quality parameters before final delivery at client's end. Clients can avail our products as per the specific requirements at industry competent prices.
    Accurate dimension
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    A DIRECT Replacement for existing T8 Fixtures
    Does not affect the original UL listing for the T8 Fixture
    Carry a REAL, 5 Year Warranty
    We may be biased, but here are 8 solid, fact based reasons why you should consider DIRECT Replacement LED Bulbs over T8....

    The ubiquitous incandescent light bulb has long been known to be an inefficient source of light. The fluorescent light bulb has superior efficiency and has, for many years, challenged its dominance, with the modern, compact fluorescent light bulb (CFL) being used to reduce domestic energy costs. It is known that there is at least a three-fold increase in efficiency (measured in lumens/watt) with these devices. Light emitting diodes (LEDs) are about as efficient as CFLs but the light produced resembles that of a spotlight, and a number of them are needed in a cluster to make a useful light source. LED clusters are used as an alternative means of lighting in both domestic and, particularly, automotive applications. The use of high power LED lighting results not only in light but heat. This heat needs to be rapidly dissipated for efficient lighting. The first lighting systems were made by mounting the LEDs onto a printed circuit board (PCB). The thermal characteristics of the glass epoxy system used in traditional PCBs are not sufficient to do this efficiently and effectively. The thermal conductivity, k, of glass epoxy, the major component in a PCB, is 0.23 W.m-1K-1. Copper conductor tracks superimposed on FR4 (PCB glass epoxy) have a thermal conductivity of 401 W.m-1K-1 and this gives an overall k of 16-17 W.m-1K-1. Mounting the assembled PCB onto an aluminum substrate gives superior thermal characteristics but the use of ESL pastes to make a solderable, insulated aluminum substrate obviates the need to deploy a PCB in the structure.
    2. Materials
    Why aluminum? Pure aluminum has a k of 237 W.m-1K-1 and copper has even better thermal conductor. If either copper or aluminum can be insulated in some way and conductors superimposed onto these insulated metals using an additive process then the thermal advantages could be used to good effect. Other substrates with good thermal characteristics such as direct bonded copper (DBC) and insulated metal substrate (IMS) have been used to fabricate power circuits but the manufacturing costs are high due to the sophisticated processes involved. Anodizing aluminum has been tried but there is some debate as to whether the insulation is sufficient to support circuitry. The insulation of copper with glasses is difficult due to the oxidation that takes place during high temperature processing in air. Furnaces that accept a flow of nitrogen can be used but the processing costs can often outweigh the advantages gained by using this metal. Aluminum at 3mm thickness can be processed in air at temperatures up to about 600°C without too much deformation of the substrate. However, the coefficient of thermal expansion (CTE) for pure aluminum is ~25ppm/°C and until now this has been considered to be a barrier for effective insulation of aluminum. An advantage of using aluminum is that its density is low at 2.70g.cm-3 copper, for example, is at least three times as dense as aluminum.
    2.1 Aluminum substrates
    Aluminum alloys are used as the preferred metal base and, in particular, 3003 alloy. All data sheets quote 3003 as the aluminum alloy substrate used for calibration purposes. It has been found that, although this alloy is readily available in the US, not every country has supply of this alloy. 3103, a close match to 3003, is readily available in Europe but Japan has difficulty in obtaining either 3003 or 3103.

    1. LED Replacement Bulbs are 30% More Efficient

    So not only do you get more light from a LED replacement bulb, they use less wattage. Our LED replacement bulbs only use 22 watts vs 28-32 watts with T8 making the LED 30% more efficient.

    2. LED Is A Directional Light Source

    The LED replacement bulbs emits light at a 110 degree pattern vs the 360 degree pattern given off by T8 fluorescent bulbs. In this case, only 30% of the light given off by the t8 fluorescent is actually hitting the intended target.

    This means you are not using all available light because the fluorescent bulb is also lighting the fixture. That's why fluorescent fixtures are brighter with reflectors.

    3. LED Transfer Light vs. Heat

    A LED fixture uses its energy to produce light. Most lighting sources including fluorescent use heat to generate light which is why traditional incandescent, metal halide and fluorescent are losing favor with property owners.

    4. LED Still Give Off Light At End-Of-Life

    A fluorescent bulb at the end of its life is very simple to spot, because it is DEAD, nothing left. A T8 bulb is considered end-of-life at 60% of its light output, which equates to roughly 14,400 hours.

    LED replacement bulbs on the other hand, calculate the end of life at 70% which is approximately 50,000 hours.

    In order to keep up with LED, you will have to replace the T8 bulbs 3.5 times

    5. LED Replacement Bulbs Have No Mercury

    One of the most important differences lies in the fact that there is no Mercury or Glass Content with LED lighting.

    In the State of Washington alone, over 10 Million lamps are disposed of in landfills each year. Those 10 Million lamps hold roughly 400 lbs of toxic Mercury waste that gets deposited each year.

    Washington State estimates that only 2 out of 10 bulbs are effectively recycled.

    6. LED Does Not Give Off UV

    LED replacement bulbs does not emit any light in the non-visible light spectrum (UV). UV/IR light causes colors to fade in fabrics, signage, while also being the leading cause for eye strain and eye fatigue.

    Fluorescent T8 bulbs emit UV/IR light.

    7. LED Makes Air Conditioning More Efficient

    LED fixtures contribute little to none in regards to heat gain in a room or air conditioned space. The LED generate less heat. Less heat means that the Air Conditioning system does not have to work as hard.

    This is vitally important if you are doing a new build or upgrade as you may be able to utilize smaller A/C systems to heat the same area.

    8. LED Provides 70% More Light

    The beam angle of the LED replacement bulb is 110 degrees. This means that all of the light generated by the LED bulb is focused in the 110 degree area.

    The T8 bulb on the other has a beam angle of 360 degrees. That means the majority of the light generated by the T8 bulb is going out the sides and top of bulb, which does not benefit the intended target.

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    Light Emitting Diodes (LEDs) have been around for years, primarily concentrated in such markets as cell phones, PDAs and other consumer electronics. Since most of these products have relatively short lifecycles, protecting LEDs wasn’t a primary concern because the product would fail or become obsolete long before the LED failed.Today, as technological advancements in LED design and processes are continually boosting light output to rival incandescent, fluorescent, and even halogen light sources, the need to protect the LEDs against heat build-up is greater than ever before.Three and five-watt LEDs are now commonplace, and industry experts are predicting 10-watt LED availability in the next few years. Power LEDs of greater than one-watt are almost always surface mounted devices.This is because the axial leads to the die in a leaded package do not conduct enough heat away from the LED. Chip-on-board (COB), ceramic submounts and other thermally efficient packages are emerging as the standard thermal management packaging solution for Power LEDs.

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    We are listed at the premium amidst the list of most valued manufacturers, suppliers, traders and exporters of LED PCB Light. This PCB is designed and made at our wide infrastructure setup, which is furnished with latest machines and other required amenities. Before final dispatch, we ensure that each product is tested by knowledgeable professionals so as to ensure their perfect surface finish.


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    Power: 3-7 Watt with Led driver
    DC: 12V-300 Amp

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