Linear ICs, which are some of the “de-energized†products that companies claim. Compared with the traditional LED driver power supply, the linear IC solution has two advantages: First, the small size can save more space for the lamp, which is beneficial to the development of the LED lamp in the direction of miniaturization; Second, the cost is low, which is beneficial to the enterprise. Cost of production.
Based on these two advantages, the linear IC solution has gradually been adopted by the majority of LED lighting downstream application manufacturers, replacing the switching power supply in some product solutions. At present, the linear scheme is widely used in bulb lamps, and most of the hot products on the market--filament lamps are also used in this scheme.
With the development of the industry, the price of LED products continues to decline, and the high cost has caused tremendous pressure on enterprises to earn profits and even survive. From the current industry situation and development trend, reducing LED production costs is the most urgent for enterprises. One of the appeals.
In 2017, the LED lighting industry as a whole has rebounded. From the first-half results announced by A-share LED companies, over 80% of enterprises achieved double growth in revenue and net profit, which greatly boosted many The confidence of small and medium-sized LED companies. However, behind the industry's recovery, another problem that has to be faced is the price increase of raw materials. While the country is vigorously rectifying high-pollution and high-emission enterprises, the LED industry has ushered in large-scale price increases including packaging materials such as copper and aluminum and paper boxes.
However, the reality is that the price hike of LED lighting downstream application companies is not obvious at present, which directly compresses the profit margin of downstream application companies. Therefore, how to reduce production costs has become one of the topics of concern for lighting companies. Linear IC solutions As a relatively low-cost application, is there still room for cost reduction?
“At present, the downstream customer group is gradually lowering the price of finished products, and the profit margin of finished products is relatively small. Now the linear scheme has been applied to the extreme by customers, and the limit is also used. Many customers save the production cost and make the power of the linear scheme. "There are some senior people in the IC field who said to the high-tech LED. "This involves the heat dissipation of the lamps. The current cooling solution is also trying to reduce costs. All electronic components are cost-saving, which ultimately leads to The product is very close to the performance 'red line'. Therefore, the product failure due to poor heat dissipation of the product and the poor stability of the product are becoming more and more frequent."
As we all know, the heat dissipation performance directly affects the service life and performance of the lamp. As we have seen, many linear solution lighting manufacturers use silicone to fill the gap between the chip and the PCB board, which in turn guides the IC to smoothly radiate heat generated by the work. However, for silica gel, it is an auxiliary heat sink. For example, the purpose of pouring silica into a bulb is to homogenize the heat. Silicone itself cannot be used as the main heat conductive material for the heat dissipation scheme.
According to the information, silica gel is a heat-conductive material with low thermal resistance and high thermal conductivity and high flexibility. The high softness of the material reduces the pressure required between the components while covering the microscopically uneven surface to allow sufficient contact of the components to improve heat transfer efficiency, making it particularly suitable for space-constrained heat transfer requirements. However, it must be mentioned that silica gel belongs to an epoxy resin. After reflow soldering or wave soldering, there will be some solder paste on the linear IC. For example, rosin, rosin can chemically react with silica gel, eventually leading to silica gel. Poor contact with IC when changing from liquid to solid. Once the IC and the silica gel are not in good contact, the heat dissipation conditions will change, the power will also drop, and even the product will fail.
According to industry insiders, current downstream customers have entered a design misunderstanding: the use of silica gel to solve the heat dissipation of the IC. However, in fact, silica gel can only play a role in assisting heat dissipation, and it does not really solve the heat dissipation problem of the IC. In what way does this problem exist? For example, a two-line IC luminaire should be used. The customer saves an IC to reduce the production cost. At this time, silica gel is used to reduce heat dissipation. This method of lighting manufacturers puts more stringent requirements on their production process. However, the opposite is true, because many manufacturers' production processes are not adequately controlled, resulting in poor contact with the IC after the silicone is filled, which in turn makes the IC poorly cooled, which may cause product power to drop or even fail. Therefore, this method of cost reduction requires manufacturers to have better process control capabilities, and it needs to be closely coordinated with AB plastics companies and design companies to verify.
In response to such problems, some insiders have called for downstream lighting manufacturers to reduce costs, but not to reduce costs without restrictions. For the linear scheme design, the senior IC field experts suggest that the customer's linear solution products will be lit under normal temperature conditions when the bare board is exposed. If the whole lamp power is only reduced by 1-2W, then the silica gel is used to assist the heat dissipation in this case, even if the product is in the follow-up During use, the silicone and linear IC are stripped, and the whole lamp power does not change greatly.
Nowadays, China has become the world's largest producer, consumer and exporter of semiconductor lighting products. With the support of relevant policy planning, China has become a semiconductor lighting country. Entering the “Thirteenth Five-Year Planâ€, the semiconductor lighting industry will usher in a new development cycle, and the linear IC solution will also gain new development opportunities. However, it should also be noted that the linear IC solution has now reached the design "red line", and downstream application manufacturers should not reduce the cost by designing the product, and the product will lose reliability.
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