Favricacion_LED_binning

This is how an LED is manufactured. What to consider?

We take a look at the manufacturing process of the LED, its components and the division into different types on which both the durability and the quality of the color it emits during its useful life will depend.

All the great productions of cinema and television They have been betting on the LED lighting. The reduction of 80% in energy and heat consumption, its 'comfort' in terms of the lower requirement of wiring, accessories and auxiliary material, in addition to its durability over time, make this new technology offer high quality results, stable and that are one step ahead of the lighting we have known so far. More light, less watts and less heat in exchange for adjustable color temperatures, cooling and ultimately, great performance.

Some secrets, obviousness and curiosities about the central component of the future of the lighting sector.

  • LEDs are classified into different categories. Understanding how they are manufactured, we understand the importance of this classification.
  • An LED is a diode through which current can only pass in one direction. A solid diode is manufactured with the addition of several layers of silicone, but a diode does not emit light on its own.
  • The LEDs emit light due to their components: Indian, Gallium and Nitrogen, which mixed together and thanks to the current, emit bluish light. For its part, by mixing aluminum with Indium and Gallium, we get a reddish light.
  • When we mix several of these components in the solid diode layers and give them electricity, we get them to light up.
  • With different mixtures of the mentioned components, different colors are achieved, but not all.
  • To achieve these more difficult colors, remote phosphor LED has been developed in which phosphorus mixtures are used on blue light to achieve higher quality in the light and expand the range of colors and make them more stable.
lighting_LED_concert

LED manufacturing: the process

When an LED is manufactured, the necessary materials are layered in a wafer between 5cm and 20cm in diameter after baking. The result obtained is not uniform, and there are always differences between the wafers. These processes often change rapidly as the industry is continually researching new techniques.

In the professional lighting sector, color quality is vital, so it is necessary to have a manufacturing system that ensures color consistency, regardless of the time of manufacture.

The classification issue comes into play here. After baking, each emitter is scored based on certain characteristics individually. Then, they are separated and classified according to the results of this evaluation. The criteria are, among others: color and intensity.

manufacturing_LED_binning

The illustration above clearly explains the concept. In this case, the blue LEDs can vary between 460 and 480 nanometers. They are divided into 5 strips of five nanometers each. The manufacturer will buy the emitters of one or another strip, depending on its interest and the use that it will give it.

In any case, the organic nature of LED manufacturing / production means that their performance is not completely predictable. This means that not all categories or stripes will always be available.

Learn to choose correctly

The brands you work with Stonex They collaborate with vendors that maintain a large stock of emitters and typologies, so that their devices have a high color consistency. Always work to achieve the highest quality chips is a maxim in premium lighting manufacturers and an obligation with artists whose work depends on always achieving the perfect color.

And now, are you going to trust anyone?

Go up