LED bulb design ideas: reduce costs by reducing the number of chips

Reduce costs by reducing the number of chips
After removing the lampshade of the LED bulb , the LED package is presented in front of you (Fig. 4, Fig. 5). LED packages with LED chips are an important part of determining light quality and are also the "most expensive part of LED bulbs" (most LED bulb manufacturers).
Figure 4: Disassemble Group A LED Bulbs
Toshiba Lighting's 7.2W products use COB -type LEDs with high luminous efficiency. Samsung 7.1W products and 7.5W products from Qinshang Optoelectronics use ordinary SMD LEDs. Recently, the number of products with high luminous efficiency in SMD has also increased, so it is impossible to simply think that only COB has excellent luminous efficiency. The manufacturer name and component function of the component are speculated by the station.
Figure 5: Package form of group B LED
The 6W product of Royal Philips Electronics of the Netherlands is equipped with the LED "LUXEON Rebel" produced by Philips Lumen, and the size of the LED chip reaches 1mm square. In order to avoid thermal stress, Philips Lumens recommends that the LED be packaged into a patterned FR-4 substrate, which is actually used. Other varieties include aluminum LED package substrates.
Most of the overseas manufacturers' LED bulbs are designed with only a small number of high-power Surface-Mounted Device (SMD) LED packages. For example, the 7W products of China Zhenmingli Holdings Co., Ltd. (Zhen Mingli Holdings) and the 6W products of Royal Philips Electronics of the Netherlands use only four SMD packages, each equipped with a large LED chip. This design "is not conducive to the uniformity of light and luminous efficiency, but has an advantage in terms of cost" (assisted technicians). The reason is that you can increase the brightness of each chip by increasing the input power of each chip, reducing the number of LED chips required. However, the heat generated by the chip will increase, so a corresponding heat dissipation mechanism is required.
In contrast, Toshiba Lighting's 7.2W product reduces the input power of each chip by using multiple small LED chips, thereby improving luminous efficiency. The company uses COB (Chip On Board) technology that directly encapsulates 96 LED chips on a substrate. Although there is a view that the cost of the LED itself will increase due to the large number of chips used, "this will improve the luminous efficiency, which not only simplifies the heat dissipation mechanism, but also does not easily cause uneven illumination." (The company) .
In addition, in this disassembly, LED suppliers of the following four products can be inferred based on the appearance of the LED. The 7.5W product of Qinshang Optoelectronics and the 6W product of Royal Philips Electronics are estimated to be equipped with LED "LUXEON Rebel" by Philips Lumileds Lighting. The 6W product of Korea Kumho Motor is estimated to be the LED of Nichia Chemical Industry, and the 7W product of Zhen Mingli Holdings is the CREE LED.
All of the above LED chips are not cheap, and the technicians who assisted in dismantling said, "If you use LEDs from Taiwanese manufacturers, you only need half the price." In this regard, Zhen Mingli Holdings said, "Because of patent issues, it has adopted Cree's LED." It seems that manufacturers cannot use cheap LEDs casually.

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