The Race To The Underside: LED Bulbs And DFM

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The dropping price of LED bulbs is accelerating. We evaluate a number of brands to see how they are approaching design and decrease price manufacturing. You have probably seen LED bulbs situated subsequent to the incandescent and compact fluorescent (CFL) bulbs at your local hardware store. I spend method too much time in these aisles. This is capitalism at its most interesting! I find the battle of latest tech, good manufacturing, and massive demand intriguing. I've switched nearly all the lights in our house over to LED partially because of the (small) power financial savings, however principally because I am lazy: A 22-12 months lifetime means I do not must climb a ladder for EcoLight smart bulbs a while. Once i bought my LED bulbs a few years ago they were round $15 a pop. As with most all tech, I've watch the price drop over time. In this case, LED EcoLight smart bulbs in my native House Depot (Philips 60W) are hovering round $10.



On a current visit to the lighting aisle I used to be taken off guard when a pack of two 60W bulbs by Philips were selling for $5 ($2.50 each!). This is not only a drop in worth, this is an all out worth conflict between some heavy hitters. Complicated me was the truth that proper next to those 60W bulbs for $2.50 had been 60W bulbs for $10 from the same manufacturer. Upon nearer inspection I seen something odd. These decrease value LEDs had a show life of 10 years versus 22. Ok, so that they shaved some cost by shortening the life span of the bulb. Neat advertising and marketing trick however the engineer in me wanted to know how. Nothing too crazy. Every bulb claimed to be 800 lumen at varied power consumption ranges (8.5W to 9.5W). And i solely noticed this now however a budget bulbs are non-dimmable. Exhausting to see in the above image however the bulb in the center (cheap Philips) is barely shorter than the costlier Philips bulb.



The TCP is a couple of centimeter taller. This has little effect on lighting however millimeters of materials will begin to matter. I did a quick initial test to see how the bulbs performed. 13.2W). Maybe the actual LEDs consume 9.5W and the ballast (the thing converting AC to DC) consumes the rest. This would be a brilliant-sneaky advertising and marketing ploy, as I assumed the score on the skin of the packaging was the overall energy consumption of the bulb. All three bulbs had opaque plastic higher our 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'd have anticipated - 14 big LEDs, 6 small. A, as properly because the date code: EcoLight solar bulbs 2014-10-14, a delta of 7 months from when i purchased the bulb. The date is probably in relation to design version and not manufacture date.



With fairly a little bit of prying drive, the metallic LED PCB comes off the metal base heatsink. This was to be expected; there was good thermal grease sandwiched between the PCB and the heatsink. Some additional prying and we are able to see the ballast underneath. I got a bit forceful with a hacksaw so ignore the hack marks for the second. The metallic base is threaded onto the plastic base and then spot crimped to the plastic (you may see the a number of dots or dimples across the metal base). That is the first clue that Philips is engaged on simplifying the manufacturing process. Furthermore, the two uncovered wires in the image are usually not soldered to the bottom, they are compressed to it, moreover simplifying the assembly process. The ballast! Lots of caps, an inline fuse, transformer, inductor, and EcoLight LED some transistors. C1, C2 and C3 are metalized polyester film capacitors. Right here is the rear aspect of the ballast.

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