The Race to the Underside: LED Bulbs And DFM
The dropping value of LED bulbs is accelerating. We examine a few manufacturers to see how they are approaching design and EcoLight bulbs lower value manufacturing. You have probably noticed LED bulbs situated next to the incandescent and EcoLight compact fluorescent (CFL) bulbs at your local hardware store. I spend way an excessive amount of time in these aisles. That is capitalism at its finest! I find the battle of latest tech, good manufacturing, and massive demand intriguing. I've switched virtually all of the lights in our home over to LED in part because of the (small) energy financial savings, however largely because I'm lazy: A 22-12 months lifetime means I don't need to climb a ladder for some time. Once i bought my LED bulbs just a few years ago they have been around $15 a pop. As with most all tech, I've watch the worth drop over time. On this case, LED bulbs in my native House Depot (Philips 60W) are hovering round $10.
On a recent visit to the lighting aisle I used to be taken off guard when a pack of two 60W bulbs by Philips have been promoting for $5 ($2.50 each!). This is not only a drop in worth, that is an all out price warfare between some heavy hitters. Complicated me was the truth that right subsequent to these 60W bulbs for $2.50 have been 60W EcoLight bulbs for $10 from the same manufacturer. Upon nearer inspection I noticed something odd. These decrease cost LEDs had a display life of 10 years versus 22. Okay, in order that they shaved some value by shortening the life span of the bulb. Neat advertising and marketing trick but the engineer in me wanted to understand how. Nothing too loopy. Every bulb claimed to be 800 lumen at numerous energy consumption levels (8.5W to 9.5W). And EcoLight i solely noticed this now but a budget bulbs are non-dimmable. Hard to see within the above picture but the bulb in the middle (low-cost Philips) is slightly shorter than the dearer Philips bulb.
The TCP is about a centimeter taller. This has little impact on lighting however millimeters of supplies will begin to matter. I did a fast initial test to see how the bulbs performed. 13.2W). Perhaps the actual LEDs devour 9.5W and the ballast (the thing converting AC to DC) consumes the rest. This would be a super-sneaky advertising ploy, as I assumed the rating on the skin of the packaging was the overall energy consumption of the bulb. All three bulbs had opaque plastic upper our bodies. The expensive Philips bulb came apart with some sturdy twisting. Underneath was a neat plastic diffuser. Under the diffuser was a mixture of small and large LEDs. Not what I'd have expected - 14 large LEDs, EcoLight bulbs 6 small. A, as properly because the date code: 2014-10-14, a delta of 7 months from once i purchased the bulb. The date is probably in relation to design version and EcoLight bulbs not manufacture date.
With fairly a bit of prying force, the steel LED PCB comes off the steel base heatsink. This was to be expected; there was good thermal grease sandwiched between the PCB and the heatsink. Some further prying and we will see the ballast underneath. I got a bit forceful with a hacksaw so ignore the hack marks for the moment. The metallic base is threaded onto the plastic base after which spot crimped to the plastic (you may see the a number of dots or dimples across the metal base). This is the first clue that Philips is working on simplifying the manufacturing course of. Moreover, the 2 exposed wires in the picture should not soldered to the bottom, they're compressed to it, moreover simplifying the meeting process. The ballast! Lots of caps, an inline fuse, transformer, inductor, and a few transistors. C1, C2 and C3 are metalized polyester movie capacitors. Right here is the rear aspect of the ballast.