The Race to the Underside: LED Bulbs And DFM
The dropping value of LED bulbs is accelerating. We compare just a few brands to see how they are approaching design and EcoLight decrease cost manufacturing. You've got in all probability noticed LED bulbs situated subsequent to the incandescent and compact fluorescent (CFL) bulbs at your native hardware retailer. I spend method a lot time in these aisles. This is capitalism at its most interesting! I find the battle of latest tech, EcoLight products sensible manufacturing, and large demand intriguing. I've switched almost the entire lights in our home over to LED in part due to the (small) energy financial savings, however largely as a result of I'm lazy: A 22-12 months lifetime means I do not must climb a ladder for a while. Once i bought my LED bulbs a few years in the past they had been round $15 a pop. As with most all tech, I've watch the price drop over time. On this case, LED energy-efficient bulbs in my local Home Depot (Philips 60W) are hovering around $10.
On a current go to to the lighting aisle I used to be taken off guard when a pack of two 60W bulbs by Philips had been promoting for energy-efficient bulbs $5 ($2.50 every!). This isn't just a drop in value, that is an all out worth battle between some heavy hitters. Complicated me was the fact that right next to these 60W bulbs for $2.50 were 60W bulbs for $10 from the same producer. Upon nearer inspection I observed something odd. These decrease price LEDs had a show life of 10 years versus 22. Okay, energy-efficient bulbs in order that they shaved some cost by shortening the life span of the bulb. Neat marketing trick however the engineer in me wished to know the way. Nothing too crazy. Each bulb claimed to be 800 lumen at varied energy consumption levels (8.5W to 9.5W). And EcoLight products i solely seen this now but the cheap bulbs are non-dimmable. Onerous to see within the above picture but the bulb in the center (low-cost Philips) is barely shorter than the costlier Philips bulb.
The TCP is a couple of centimeter taller. This has little impact on lighting but millimeters of materials will begin to matter. I did a quick preliminary take a look at to see how the bulbs carried out. 13.2W). Perhaps the actual LEDs devour 9.5W and the ballast (the factor changing AC to DC) consumes the rest. This could be an excellent-sneaky advertising and marketing ploy, as I assumed the rating on the surface of the packaging was the general power consumption of the bulb. All three bulbs had opaque plastic upper bodies. The costly Philips bulb got here apart with some robust twisting. Beneath was a neat plastic diffuser. Under the diffuser was a mixture of small and huge LEDs. Not what I might have expected - 14 huge LEDs, 6 small. A, as effectively because the date code: 2014-10-14, a delta of 7 months from after i bought the bulb. The date might be in relation to design model and never manufacture date.
With fairly a bit of prying power, the metallic LED PCB comes off the metal base heatsink. This was to be anticipated; there was good thermal grease sandwiched between the PCB and the heatsink. Some additional prying and we are able to see the ballast beneath. I obtained a bit forceful with a hacksaw so ignore the hack marks for the second. The steel base is threaded onto the plastic base and then spot crimped to the plastic (you'll be able to see the a number of dots or dimples around the steel base). This is the primary clue that Philips is working on simplifying the manufacturing process. Moreover, the 2 uncovered wires in the picture usually are not soldered to the bottom, they're compressed to it, moreover simplifying the assembly process. The ballast! A number of caps, an inline fuse, transformer, inductor, and some transistors. C1, C2 and C3 are metalized polyester movie capacitors. Right here is the rear side of the ballast.