Solid State Lighting Reliability: Components to Systems

618 Pages·2013·15.108 MB·English

by  T. de Groot, T. Vos, R. J. M. J. Vogels (auth.), W.D. van Driel, X.J. Fan (eds.)

Solid State Lighting Technology
and Application Series
Series Editor
G.Q. Zhang
For furthervolumes:
http://www.springer.com/series/8864

W.D. van Driel X.J. Fan
l
Editors
Solid State Lighting
Reliability
Components to Systems
Editors
W.D.vanDriel X.J.Fan
PhilipsLighting DepartmentofMechanicalEngineering
Eindhoven,TheNetherlands LamarUniversity
Beaumont,TX,USA
ISBN978-1-4614-3066-7 ISBN978-1-4614-3067-4(eBook)
DOI10.1007/978-1-4614-3067-4
SpringerNewYorkHeidelbergDordrechtLondon
LibraryofCongressControlNumber:2012943579
#SpringerScience+BusinessMedia,LLC2013
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Preface
Solid state lighting (SSL) is recognized as the second revolution in the history of
lighting.Theprimaryreasonistheannualglobalenergybillsavingof€300billion
and a reduction of 1,000 MT of CO emission. As such, the SSL industry is
2
expectedtoexceed€80billionby2020,whichwillinturncreatenewemployment
opportunities and revenues. A second reason is the promise of a long useful
lifetime, with claims up to 80,000 h. As with any products, the consistency and
reliability of SSL systems need to be ensured before they can be adopted in
any applications. To add to the complexity, there is also a need to ensure that the
cost of this technology needs to be comparable or even lower than the current
technology.AlthoughSSLsystemswithlowreliabilityrequirementshavealready
been developed, they can only be used in applications that operate in modest
environments or in noncritical applications. For demanding applications in terms
of environmental conditions, such as automotive application, or where strict
consistencyisneeded,suchashealthcareapplicationsandhorticultureapplications,
theconventionallightingsourcesarecurrentlystillpreferreduntilthereliabilityof
SSL is proven in these applications. Therefore, the knowledge of reliability is
crucial for the business success of SSL, but it is also a very scientific challenge.
Inprinciple,allcomponents(LEDs,optics,driveelectronics,controls,andthermal
design) as well as the integrated system must live equally long and be highly
efficient in order to fully utilize the product lifetime, compete with conventional
lightsources,andsaveenergy.
It is currently not possible to qualify the SSL lifetime (10 years and beyond)
beforetheseproductsareavailableinthecommercialmarket.Thisisarathernew
challenge,since typical consumer electronics devices are expected tofunction for
only2–3years.Predictingthereliabilityoftraditionalelectronicsdevicesisalready
very challenging due to their multidisciplinary issues, as well as their strong
dependence on materials, design, manufacturing, and application. Predicting SSL
reliability will be even more challenging since they are comprised of several
levels and length scales of different failure modes. The tendency towards system
integration, via advanced luminaries, System-in-Package approaches, and even
heterogeneous3DintegrationsposesanadditionalchallengeonSSLreliability.
v
vi Preface
AfunctionalSSLsystemcomprisesdifferentfunctionalsubsystemsworkingin
close collaboration. These subsystems include the optics, drive electronics,
controls,andthermaldesign.Hence,thereisalsoaneedtoaddresstheinteraction
between the different subsystems. Furthermore, an added challenge for system
reliability is that accelerated testing condition for one subsystem is often too
harsh for another subsystem. Alternatively, even the highest acceleration rate
possible for one subsystem may be too low to be of any use for yet another
subsystem. Hence, new techniques and methodologies are needed to accurately
predict the system-level reliability of SSL systems. This would require advanced
reliabilitytestingmethods,since today’s availablestandardsaremainlyproviding
theprobabilityatwhichLEDsmayfailwithinacertainamountoftime.
Today, no open literature that covers the reliability aspects for SSL exists,
rangingfromtheLightEmittingDiode(LED)tothetotalluminiareofasystemof
luminaries.Thisbookwillprovidethestate-of-the-artknowledgeandinformation
onthereliabilityofSSLsystems.ItaimstobeareferencebookforSSLreliability
fromtheperformanceofthe(sub-)componentstothetotalsystem.Thereliabilityof
LEDs and all other components (optics, drive electronics, controls, and thermal
design)aswellastheintegratedsystemofanSSLluminiarewillbecovered.Various
failure modes inSSL luminiare will be discussed. Different reliability testing and
luminiare reliability testing performance will be introduced. The content has an
optimalbalancebetweentheoreticalknowledgeandindustrialapplications,written
by the leading experts with both profound theoretical achievement and rich
industrial experience. Parts of the contents are firsthand results from research and
developmentprojects.
ThisbookispartofaseriesonSolidStateLighting,editedbyProf.G.Q.Zhang.
The series will systematically cover all key issues of solid state lighting
technologiesandapplications.
Eindhoven,TheNetherlands W.D.vanDriel
Beaumont,TX,USA X.J.Fan
Acknowledgments
Wewouldliketothankalltheauthorsfortheircontributionstothebook.vanDriel
andZhangwouldalsoliketomakeacknowledgmentstomanyoftheircolleaguesin
PhilipsandtheDelftUniversityofTechnologywhohavecontributedtothisbookin
onewayoranother.
van Driel is grateful to his wife Ruth Doomernik and their two sons, Juul and
Mats, for their support and love. Fan is grateful to his parents for their unselfish
supportandlove.
Delft,TheNetherlands G.Q.Zhang
vii

Contents
1 QualityandReliabilityinSolid-StateLighting......................... 1
T.deGroot,T.Vos,R.J.M.J.Vogels,andW.D.vanDriel
2 Solid-StateLightingTechnologyinaNutshell.......................... 13
C.A.Yuan,C.N.Han,H.M.Liu,andW.D.vanDriel
3 FailureMechanismsandReliabilityIssuesinLEDs................... 43
M.G.PechtandMoon-HwanChang
4 FailureModesandFailureAnalysis..................................... 111
J.F.J.M.CaersandX.J.Zhao
5 DegradationMechanismsinLEDPackages............................ 185
S.Koh,W.D.vanDriel,C.A.Yuan,andG.Q.Zhang
6 AnIntroductiontoDriverReliability.................................... 207
S.Tarashioon
7 HighlyAcceleratedTestingforLEDModules,Drivers,
andSystems.................................................................. 231
D.SchenkelaarsandW.D.vanDriel
8 ReliabilityEngineeringforDriverElectronics
inSolid-StateLightingProducts.......................................... 243
AbhijitDasgupta,KoustavSinha,andJaemiHerzberger
9 SolderJointReliabilityinSolid-StateLightingApplications........ 285
J.Kloosterman,R.Kregting,M.Erinc,andW.D.vanDriel
10 AMultiscaleApproachforInterfacialDelamination
inSolid-StateLighting...................................................... 305
H.FanandM.M.F.Yuen
ix
x Contents
11 OntheEffectofMicroscopicSurfaceRoughness
onMacroscopicPolymer–MetalAdhesion.............................. 317
O.vanderSluis,S.P.MNoijen,andP.H.M.Timmermans
12 AnIntroductiontoSystemReliability
forSolid-StateLighting.................................................... 329
W.D.vanDriel,F.E.Evertz,J.J.M.Zaal,
O.MoralesNa´poles,andC.A.Yuan
13 SolidStateLightingSystemReliability.................................. 347
M.H.Schuld,B.F.Schriever,andJ.W.Bikker
14 PrognosticsandHealthManagement.................................... 373
M.G.Pecht
15 FaultTolerantControlofLargeLEDSystems......................... 395
JianfeiDong,W.D.vanDriel,andG.Q.Zhang
16 LEDRetrofitLampsReliability........................................... 413
XiuPengLiandChenMei
17 SSLCaseStudy:Package,Module,andSystem....................... 427
DaoguoYangandMiaoCai
18 HierarchicalReliabilityAssessmentModels
forNovelLED-BasedRecessedDownLightingSystems.............. 455
BongtaeHan,Bong-MinSong,andMehmetArik
19 DesignforReliabilityofSolidStateLightingProducts............... 497
LiyuYangandXiantaoYan
20 ColorConsistencyReliabilityofLEDSystems......................... 557
B.Bataillou,N.Piskun,andR.Maxime
21 ReliabilityConsiderationsforAdvanced
andIntegratedLEDSystems.............................................. 591
X.J.Fan
Index................................................................................ 613