LED Packaging Technologies

Luruthudass Annaniah is the Director of Product Development at ams OSRAM Penang, Malaysia, and an Adjunct Lecturer of University Technology Petronas, Malaysia.Mohamed Salleh M. Saheed works at Infineon Technologies (Kulim), Malaysia, as Technical Project Leader in Technology, Development and Innovation Department, specializing in Semiconductor Power Devices for automotive and industrial applications.Rajan Jose is a senior Professor in the Universiti Malaysia Pahang (UMP), Malaysia, and is the Associate Editor-in-Chief of the Springer Nature journal Materials Circular Economy.

• About the Authors viiPreface ixAcknowledgments xiii1 A Brief History of Artificial Light and LED Packaging 1 1.1 Evolution in Artificial Light 11.2 Impact of Light-Emitting Diode on the World 41.3 LED Industrial Chain 61.4 Evolution in LED Packaging Technology 81.4.1 Low-Power Package Evolution 121.4.2 Mid-Power LED Packages 141.4.3 LED High-Power and Ultra-High-Power Packages 151.5 Summary 17References 182 Fundamentals of LED Packaging Technology 19 2.1 Effective Light Extraction 192.1.1 Theory of Light Conversion in LED 212.1.2 Light Extraction Based on Chip Technology 232.1.2.1 Chip Surface Roughing 252.1.2.2 Buried Micro-Reflectors Chip 262.1.2.3 Chip Geometrical Shaping and Type 262.1.3 Light Extraction Based on High Reflective Packaging Material 282.1.3.1 Leadframe Plating Surface Influence 282.1.3.2 Housing Material Reflectivity 292.1.3.3 Encapsulation Material Light Extraction Efficacy 292.1.4 Optical Interface Enhancing Light Extraction 312.2 Package Design and Encapsulation Technology 322.2.1 Package Design 322.2.1.1 Design for Cost 332.2.1.2 Design for Reliability 342.2.1.3 Design for Manufacturing 342.2.1.4 Design for Testing 342.2.1.5 Design for Environment 362.2.1.6 Design for Assembly at Second Level PCB Board 362.2.1.7 Design for Effective Light Extraction 372.2.2 Encapsulation of LED 372.2.2.1 Epoxy, Silicone, and Hybrid Compound Encapsulation 372.2.2.2 Hermetic Sealed Package – Metal Can 402.2.2.3 Epoxy Cap Encapsulation 412.2.2.4 Glass Cap on Ceramic or Aluminum Encapsulation 412.3 LED Thermal Management 422.3.1 Fundamental of the LED Thermal Behaviors 422.3.2 Thermal Design in LED Package 462.3.3 Impact of Thermal Behavior of an LED on Its Performance 482.4 Electrical Contact Design 492.5 LED Light Conversion Principle 502.6 Summary 50References 513 LED Packaging Manufacturing Technology 53 3.1 LED Packaging Process Flow 533.1.1 Die-Attach Process 533.1.1.1 Die-Attach and Glue Curing Process 553.1.2 Wire Bonding Process 563.1.3 Surveillance Checking Using Statistical Process Control 583.1.4 Encapsulation Process and Post-Mold Curing Process 603.1.5 Singulation Process 623.1.6 Final Test and Auto Vision System Process 623.1.7 Packing Process 633.2 Common Defects in LED Packaging Industry 653.2.1 Die-crack: Impact on the Electrical and Optical Properties of LED 653.2.2 Lifted Die or Glue: Impact on LED Thermal Behavior and LED Performance 673.2.3 Wire Interconnect Defects: Impact on LED Electro-optical Quality 693.3 Summary 70References 704 LED Automotive Lighting Application Technology 71 4.1 Basic Science of Light for Automotive – The Photometric 724.1.1 Light Intensity 724.1.2 Luminous Flux 734.1.3 Illuminance 744.1.4 Luminance 744.1.5 Luminous Efficacy 744.2 Lighting – Light Projection “To See” 744.2.1 Headlamp 754.2.2 Adaptive Front-Lighting System – Headlamp 774.2.3 Optical Concept Automotive Front Lighting – Headlamp 804.2.4 Future of LED Headlamp Technology 814.2.5 LED Headlamp Thermal Management 824.3 Signaling – Lights That Are “To Be Seen” 834.3.1 AFL – Day Running Light 844.3.2 ARL – Signaling Lights 854.3.3 Optic Concepts of Signaling Light “To Be Seen” 864.3.3.1 Reflective and Refractive Optics 864.3.3.2 Light Guide Optics 874.4 Interior Lighting 924.5 Summary 93References 935 LED Application For Consumer Industry 95 5.1 Consumer Indoor Lighting 955.2 Health Care and Medical Treatments 965.3 Safety and Security 985.3.1 Led in Iris Recognition System 985.3.2 LED in Food Processing 1005.3.3 Treatment in Solid and Liquid Foods 1015.3.4 Water Treatment 102 References 1026 LED Application for General Lighting 105 6.1 RETROFIT Lighting 1056.1.1 RETROFIT Lamp 1076.1.2 Hospitality Lighting – Architecture Lighting 1116.2 LEDfit Lighting 1126.2.1 Residential Lighting – Living Room Down Lighting 1126.2.2 LED Street Lighting 1136.2.3 Exterior Architectural Lighting 1176.2.4 Horticulture Lighting Application 1186.2.4.1 Photosynthesis 1196.2.5 Photomorphogenesis 1206.2.5.1 Impact of LED Light on Horticulture Industry 1216.3 Summary 122References 1237 Quantum LEDs 125 7.1 Quantum LED as the Alternative to Organic LED 1257.2 Fundamentals of Quantum Dot 1257.3 Quantum Dots in LED 1297.4 Quantum LED Structures 1307.5 QD-LED Fabrication 132References 1348 Ultraviolet LED Packaging and Application 137 8.1 UV LED Application 1378.2 UV-A and B LED Packaging Technology 1408.3 UV-C Packaging Technology 1428.4 Future Application of UV-LED and Packaging Design Evolution 1438.4.1 Novel Liquid Packaging Structure 1438.5 Impact of UV-LED to UV Light Source Business 1448.6 Summary 144References 1459 Lifecycle Analysis and Circular Economy of LEDs 147 9.1 Introduction 1479.2 LCA of LEDs 1489.2.1 Materials Footprint 1499.2.2 Embodied Energy and Carbon Footprint 1519.3 Circular Economy of LEDs 1529.3.1 Lower Material Quantities by Design and Enhanced Material Properties 1539.3.2 Materials with Multifunctionalities 1549.3.3 Materials of Higher Circularity 1559.3.4 Materials with Enhanced Durability 1569.3.5 Materials with Reduced Carbon Footprint and Embodied Energy 1569.3.6 Material Miles 1579.3.7 Sustainable Materials from Renewable, Recycled, and Recovered Sources 1579.3.8 Materials with Higher Environmental Benignity 1579.3.9 Materials with No Adverse Human Health Effects 1579.3.10 Materials Enabling Healthy Natural Habitat 158References 158Index 159