The growth of the LED industry has been enormous since the 1960′s when LEDs first entered the market. The efficiency and light output of these devices has risen exponentially, doubling every 36 months. The growth has mainly been attributed to parallel developments of semi-conductor technologies and advances in both material and optic sciences. Another reason for this growth, however, is the wide variety of applications in which LEDs can be utilized.

Most everyone can relate to any one of the many visual LED applications. By a visual application, we are referring to a visual signal where light travels from the source to the human eye to convey a specific message or meaning that can be quickly understood. You can see them practically everywhere you look including status indicators, equivalent display, message displays on railways, trains, trams and ferries, traffic signals, signs, vehicle turn signals and brake lights and even such simple applications as glow lights and LED art. There are also many visual applications that you may not immediately think of such as decorative displays, TV and laptop backlighting, DLP Projectors, night vision devices, security cameras, aviation instruments and there are even applications from NASA using LEDs that have been instituted to promote astronaut health.

The portion of the LED field that uses non-visual LEDs can include broadband data, wireless transmitters, access points for data transfer, optical fiber and freespace optical communication, remote controls, movement sensors, photodiodes, sterilization, UV curing devices, machine vision, voltage references and even on the latest and greatest flatbed scanners.

There are many systems that rely on a light source for operation and communication. There are also a myriad of reasons that LEDs are dominating this market more everyday.  Among these reasons are the following:

• Instant On and Off Switching
• Low Cost
• Optimum Design Flexibility
• Repeatability
• Color and Wavelength Variation
• Uniform Light Display
• Low Power Consumption
• High Speed Response
• Long Life Cycle
• Low maintenance

VCC Optoelectronics has a wide variety of LEDs for your visual and nonvisual applications. We also have a staff of knowledgeable experts to help you implement your ideas and value-added services if you need some extra staff to carry out the design, prototyping, production and other parts of your project. Simply contact us and one of our engineers will speak with you to evaluate your needs and provide reliable and detailed assistance for your application development.

The goals of sustainability, renew-ability, power reduction, lowered carbon footprints, reduced refuse and increased efficiency are global. Smart lighting is one of the key strategies in this global purpose. LEDs are crucial to this technology and being implemented in signaling, data transmission, wireless transmitters, remote controls, architecture and more.

Recent standards from the Infrared Data Association(IrDA), United States Green Building Council (USGBC) and other groups such as Energy Star are calling for higher standards in these areas to achieve a more sustainable future.  We are closer than ever to making a world where lighting is digital, efficient and increases the health and welfare of all.

Smart Lighting through the use of LEDs meets all of these goals and offers improvements that years ago were thought to be impossible. LEDs are Eco-friendly as the components are 95% recyclable. This reduces refuse and ensures sustainability. They are also wonders of efficiency using significantly less power than traditional lighting options. LEDs comply with Energy Star standards and requirements as they use anywhere from 30% (over fluorescents) to 120% (over incandescents) less power and save 3000 times their own weight in greenhouse gases. The shock and vibration resistant characteristics contribute to longer life cycles, up to 50 times that of other lighting options. This not only reduces replacement costs but the maintenance costs and personnel associated with servicing the circuitry.

Smart lighting technologies using LEDs generate less heat, thereby allowing for more LED devices to be installed in smaller devices. The light is more focused and saturated, without color fading, providing brighter displays and increased variety in the colors and types of displays that are designed.

The ability of LEDs to be switched off and on millions of times per second have permitted them to be used in data transmission circuits, wireless transmitters, lasers and also as access points for data transport. For example, current IrDA standards call for LEDs to be used in all broadband transport, a high-speed communication platform that years ago was a dream.

VCC carries a line of efficient, high quality digital LEDs for all of your smart lighting applications. Whether you are developing an optical signaling circuit, data transmission design, backlighting set-up, control panel or any number of additional smart lighting designs, we have the LEDS, lite pipes and PCB components to make your design work. Contact one of our always available experts today to discuss, plan and even receive design assistance for making your innovative ideas come into fruition.

Designing for extreme conditions in ambient environments adds a whole new level of difficulty to LED circuitry and design. By extreme, we mean projects where there is an abnormally high or excessive exposure to any of the following: heat, cold, humidity, vibration, dust, moisture, chemicals, contamination, vacuum, radiation or extreme temperature changes.

To overcome extreme environmental conditions, there are a number of design considerations and requirements that can be included to improve reliability and performance. Among these considerations are:

Clear Understanding of System Requirements – When implementing an LED circuit in extreme conditions, a clear understanding of what is essential is mandatory. The ambient environment will present enough challenges so system design should be as simple and compact as possible. In many cases, engineers are encouraged to add special features such as added colors, graphics or other bells and whistles. This is one case in which these temptations should be avoided. Keeping the LED circuitry to the minimum required to meet specifications not only will reduce possible failures but also reduce testing and manufacturing times and thus development cost.

Review of System Options and Costs – Before the design begins, a thorough review of different technologies and the costs involved will improve the LED design and help keep costs to a minimum.

Addition of Components to Compensate for Extreme Conditions – There are a number of LEDs that are available for implementation in extreme environments. Already the most reliable lighting device, LEDs are also available with special viewing angles, power levels, moisture sealants and more. In addition to LEDs that meet extreme environmental conditions, additional components can be implemented to overcome vibration, heat and cold extremes such as stabilizers, fans and on-board heaters.

Redundant Components – The most critical components and LED signals should be designed in a manner where there is a back up to the main device.

System Testing, Modeling and Evaluation – System testing, modeling and evaluation is the most important design component when engineering for extreme conditions. A detailed description of testing, the purpose for the testing, data evaluation techniques, resources and modeling may consume more time during design but can save time, money and reputation in the long run.

Alternative Design Options – Preparation is key in all system design but especially when designing for an extreme environment. Having a ‘Plan B’ that can be quickly implemented to help or replace your original design will save time and frustration. The problem in not planning for alternatives is that if your initial plan or evaluation isn’t right, you must return to the drawing board instead of simply putting Plan B into motion.

VCC has experts with considerable LED and design knowledge to help with all your projects. If you have questions about special LED components that are available or other extreme design considerations, contact VCC today and you will find we are ready and able to help.

Today’s economic environment has driven a need for retrofitting equipment, signage and other electronic devices to meet new production requirements instead of replacement. The goal of redesigning is to keep the cost at a level that is considerably less than designing and manufacturing a new item or piece of equipment. Engineers are faced with the challenge of changing an existing panel board, display or product in a way that meets or exceeds requirements at minimum cost and with a quick turn-around time.

Why Should I Use Litepipes in My Retrofit Project?

Using Litepipes in retrofit situations can provide a number of benefits for the designer, company and product. Among those benefits are:

• Avoid LED Replacement – Many times the redesign of equipment will not change the desired LED color or power levels but the designer may want them displayed in a different panel area, shape or configuration and may even require them to be viewed from another location. Implementing a litepipe in this situation can allow the designer to keep the circuit LEDs and allow them to be extended to a different panel location, shown as a different shape or be presented in a different configuration.
• No Additional Wiring – Litepipe installation in retrofit applications allow the Engineer to change the lighting and indication layout without requiring additional wiring to be added to the design. This saves cost in material, assembly.
• Flexibility – Litepipes that are used in retrofit projects provide Engineers and Designers to have extensive flexibility when re-designing a product or piece of equipment. The exact location of circuit boards becomes a variable instead of a critical issue. If new components must be added to the device and the PCB moves, or if the panel must move, a lite pipe allows for the light to be extended to the panel or sign surface without being limited by PCB or LED location.
• Increased Visibility – VCC Litepipe have a 160-degree viewing angle, most likely this is considerably more viewable from more locations.
• Meet Power and Efficiency Standards – What’s the best way to meet efficiency and power conservation standards? Don’t add components that require more power, like, you guessed it, litepipes. The wave of the future is conservation and the use of litepipes will help you meet these goals.

VCC litepipes are available for surface mount or thru-hole LEDs and allow that light to be extended to the desired surface.  They are available in moisture sealed configurations for wet or exposed locations and also with increased flexibility of the litepipe (Flexfire series) itself for applications where a bend or bend(s) may be required. The litepipe end can be ordered in square, round or rectangular panel connections to meet practically any retrofit design need. Contact us today for more information on how the VCC Litepipe series can meet and exceed your retrofit needs.

Most factories, homes, schools and businesses that are undertaking remodeling or upgrade projects for their lighting systems are investigating and giving serious consideration to the use of LEDs. Everything from architectural lighting, security lighting, remote control applications, signage and more can benefit from the many features of LED lighting and signaling. Groups such as the ALA – American Lighting Association, CEE –Consortium for Energy Efficiency and the DOE – Department of Energy, have recognized new LED lights and recommend their use.

There are a number of reasons that LED lighting is taking over upgrade and improvement projects but the dominant reasons are listed below:

Cost – First and foremost, our upgrade projects operate on a budget. Each component must be selected with cost in mind. LEDs are cost competitive with other lighting options with the added benefits of faster ROI. LED circuits are 75-80% more efficient and consume less power providing instant savings over other options once installed.

Life cycle – Once an LED application has been installed, the maintenance and replacements cost are minimal. Whether it be room lighting, media or advertising signs or a backlit scoreboard in a school gym, LEDs will cost less in future replacement as they have a five to ten year life cycle. For hard to reach applications such as the aforementioned scoreboard or a parking lot light, the replacement savings alone can be considerable in addition to freeing up the maintenance staff to address other building needs.

Brightness – In LED applications such as signs and security indicators, the brightness and color spectrum are greater with LED applications than any other type of standard lighting options. This characteristic is especially beneficial to outdoor locations where fog and other bad weather can reduce visibility and also for long distance viewing purposes.

Control – LEDs are much easier to add to Building Automation Systems or even a PLC controlled production machine. The instant on/off and pulsing abilities of LEDs allow for a boundless set of options. You can connect room lighting to an occupancy sensor, provides production floor communication or advertise your product with a scrolling or flashing message. If you can dream it up, it can be automated with an application featuring LEDs.

VCC offers a wide range of LEDs for signaling, backlighting and communication applications. We also offer Value Added services from Consultation to complete Project Management to assist you in your lighting and signaling upgrade projects. Simply contact us today and let our experienced personnel and global sourcing abilities resolve the questions and offer improvements for your project.

Code, specification or circuitry changes, inventory errors, forecasting changes and missing or damaged parts are all challenges faced in the development and production of both new and established printed circuit board based equipment. In accordance with Murphy’s Law, inventory deficiencies inevitably occur when a supply chain schedule is already behind or when a client needs their part in an expeditious manner. The department foreman and supply chain management personnel are often in a panic, and burdened with the undesirable job of informing upper management or clientele that his department is unable to meet or advance production schedules without a acquiring specific components such as an LED, standoff, connector or lite pipe device.

Supply and demand is a basic economic principle that has taken on a new meaning in today’s production environment. The days when the electrical stockroom was packed with all the possible elements needed to produce a variety of circuits or circuit boards is gone. Such an inventory would quickly become outdated and obsolete as the advancement of technology present today demands a malleable inventory, ready to change without months, weeks or at times, even days of notice. New developments, ideas and product improvements mean that inventory must be fluid, ever ready to change and adapt to new requirements. While this idea sounds great in writing, realistically, it’s a hard goal to meet.

One way many production facilities are overcoming this challenge is to develop relationships with suppliers that permit on-demand supply of the most critical components, which in today’s circuitry world includes PCB components, LEDs, Lite pipes and other elements. On-demand PCB component supplies allow you to reduce stock levels while still decreasing process times as you can procure system components at the right time and in the right quantity to complete even advanced production schedules.

Every production facility pursues ways to fine-tune Supply Chain Management, determined to meet unexpected changes without production downtime and to seamlessly overcome data and forecasting deficiencies. The advantage of on-demand supply is that it offers you a virtual inventory that can be on its way to your facility simply by placing a call, writing an e-mail or clicking an online order button. It provides production and lifecycle equilibrium, permitting your facility to better manage the flow of strategic inventory reserves. Components that can be received ‘on-demand’ allow you to reduce inventory of that item without the challenges associated with lower inventory counts. Inventory space can then be used for components that aren’t available on-demand, to enhance the production floor or to store completed products.

VCC Optoelectronics offers on-demand supply of various PCB components, LEDS and Litepipes to help your production facility become and remain highly flexible, quickly able to adapt to the ever-changing product development environment. Call or e-mail us today and begin a relationship with our professional staff who can help you set-up receipt of our large number of ‘always in stock’ elements.

Through Hole (Thru-hole) PCB Assembly

Through-hole PCB assemblies, more commonly referred to as “thru-hole” are constructed with components that have long leads that are inserted into plated thru-holes on printed circuit boards. Components are then soldered into place and connected to its specified circuit.

What are the Advantages and Disadvantages of Thru-hole PCB Assembly?

Thru-hole PCB assembly out performed all previous PCB assembly types until Surface Mount Technology (see below) made its appearance. It provides better reliability and continuity than older technologies such as point-to-point assembly. It even holds one advantage over the popular surface mounted assemblies; its strong mechanical bond. Printed circuit boards that are mounted in high vibration applications will often use the assembly type. They are also used in many test and prototype applications, as it is easier to remove or interchange parts without damaging the board.

The disadvantages of thru-hole assembly includes the cost of drilling and plating the thru-holes themselves as well as the limited routing area available after the component is soldered in place. It also limits you to use of only one side of the printed circuit board.

Surface Mount PCB Assembly

PCB assemblies with surface mounted components are referred to as SMT (Surface Mounted technology) assemblies. In SMT assemblies, components are mounted directly to the surface of the printed circuit board.

This method of PCB assembly allows the use of smaller components with small leads and short pins, flat contact or even terminations mounted on the component itself. Surface Mounted Devices (SMD) can be as much as one-tenth the size and weight of thru-hole parts. This assembly type also permits use of both printed circuit board sides. This PCB assembly type is favored in automation, computer assembly and other applications that can reduce product cost and increase production rates.

What are the Advantages and Disadvantages of Surface Mount PCB Assembly?

Surface Mount PCB Assemblies have a large number of advantages over thru-hole technology, including the smaller and less expensive components, fewer plated thru-holes drilled into the PCB and the use of both sides of the printed circuit board. Using both PCB sides permits a much higher number of components and many more connections per component.

Disadvantages of Surface Mount PCB Assemblies are that manual adjustments or replacements are more difficult in testing and prototype applications. In addition, as components and trace circuits become smaller, reliability of the circuitry and solder joints can become a concern.

Who Can Provide Me with Both Surface Mounted and Thru-Hole Type PCB Components?

The selection of PCB components offered by VCC Optoelectronics includes a variety of LEDs, Interconnections, Panel Mount and Clips for all your PCB assembly requirements. Our professional sales and engineering staff is available to assist your selection process and provide reliable components right when you need them. Contact VCC today for more details.

LEDs began their automotive use in the 1980’s with the first LED center high-mounted stop lamp found in the 1984 corvette. Growth in the automotive industry was slow for LEDs and it wasn’t until the 2000 Cadillac Deville was released that LEDs supplied the entire rear cluster of stop lamps. Since that time, LED use has quickly taken over the automotive industry with close to 95% of both interior and exterior lighting being provided by LEDs. This includes the front headlamps, side indicators, rear stop lamps, auxiliary lamps, interior dashboard and overhead lighting.

Why the Rapid Change to LED Use in Automobiles?

The first years of LED development, from the 1970’s to the mid- 1990’s saw significant increases in the brightness and control of LEDs. Since the 1990’s innovation in the material and design of LEDs has provided such increases in luminosity that LEDs have become the most practical, flexible and cost effective selection for all automotive indication and lighting needs.

What Additional Benefits Do LEDs Provide in automotive applications?

The list of benefits that LEDs provide over standard lighting options is vast and includes:

• Long service life – Most LEDs will outlast the automotive system in which they currently operate. As opposed to previous lighting and indicator lamps with hundreds of hours of operation, LEDs offer thousands of hours. This is critical for high use applications such as DRLs (Daytime Running Lamps).
• Extremely resistant to vibration and stress – LEDs have no moving components and no small filaments that can be jostled about and broken as vehicles travel up and down the nation’s roadways.
• Better performance – LEDs reach full intensity faster than it’s predecessors. For application such as brake lights, the few milliseconds of speed in reaching full intensity provides increased safety.
• Reduced vehicle downtime – In commercial vehicle applications, the stability and strength of LED device operation provides increased profits as the vehicle spends less time out of commission.
• New styling potential – The flexibility in design and placement of LEDs allows manufacturers to provide distinctions between models through their lighting design.
• Reduced design space – LEDs are low profile and compact compared to other lamp alternatives. This increases design options and allows other components to be added in the space saved from lamp placement.
• High Efficiency – LEDs are highly efficient and help reduce the overall heat of the lighting system. Heat that is generated can be easily managed with heat sinks and fans.
• No Hazardous Gases or IR Radiation – Everything we produce today and every way we produce it, contributes to the improvement or degradation of the environment. LEDs do not contain hazardous gases nor do they emit IR Radiation, which places them at the top of environmentally responsible lighting choices.

VCC offers an array of LED indicators that can be implemented in a wide variety of automotive applications. Contact us today for more information and assistance in your automotive LED application needs.

Connecting light-emitting diodes (LEDs) to circuit boards is a matter of some question if you ask the experts. There are those who swear by the age-old method of soldering with lead because of its simplicity and commonality. But VCC’s products are far from ordinary and our new techniques have created several alternatives that come with significant advantages not only for the manufacturing process, but also for the end user.

Problems with Traditional Soldering Techniques

Traditionally, LEDs have been constructed using time-tested soldering techniques. This type of construction method is especially popular for through-hole LEDs where the leads pass through the circuit board, as opposed to surface-mount LEDs that sit on the surface of the board. When LEDs are connected to circuit boards using this method, care must be taken to connect the LED in the correct direction with respect to the anode (a) or + and the cathode (k) or -.

Soldering works by melting an alloy – usually tin and lead in a 60% to 40% ratio – tinning the surface with the alloy and connecting the two components. But herein lies the first problem: lead is a heavy metal and is considered highly poisonous to humans and damaging to the environment as well. The second problem with this process is the potential for damage to the LED as a result of the high heat (200°C).

Damage can also occur when errors are made during the connection process. If an LED is incorrectly connected using soldering or otherwise needs to be removed from the board (a process called desoldering), the removal can often damage the LED.

Superior Interconnectors for LEDs

VCC uses state-of-the-art alternative techniques for connecting LEDs: either panel mount assemblies or locking header connectors. Panel mounting assemblies used by VCC are fast, simple, and highly advantageous. Not only is panel mounting a tool-free technique, but by using press-fit or threaded connections, VCC is able to provide a variety of LED connections to power source circuitry.

VCC’s locking header connectors are designed to provide positive locking for securing connectors to a printed circuit board using a male pin header design. Using existing friction header designs, VCC incorporated a finger release lever with a detent which creates a polarized positive locking header – our “click, it’s locked” feature. Removing the ramp connector from the locking header involves inserting a fingertip between connector and header lever to disengage the lock, which allows the connector to be extracted. This locking header also provides polarity protection by preventing the header connector from being inserted in the reverse position.

By choosing alternative interconnections to the standard soldering methodology, VCC is a leader in the field with simpler, easier mechanisms and a more environmentally-friendly outcome.

A light-emitting diode (LED) is generally made with the same basic components. In the simplest sense, the LED circuit consists of two components connected in a series—an LED and a current limiting resistor—that are powered by a voltage source. The basic components of an LED include the following:

• Die: Includes a top contact that is wire-bonded to the frame terminal called the post
• Lead frame: This houses the die
• Encapsulation epoxy: This protects the die and disperses the light
• Conductive epoxy: Recessed in one half of the frame
• Anvil: A recess in the frame which is specifically shaped to throw light forward

At the heart of LED construction is the p-n junction which functions as a semiconductor diode. Every LED contains a p-type semiconductor (electron rich) and n-type semiconductor (electron deficient) with a transition layer between them known as the p-n junction. Connecting the LED to an energy source results in the flow of current from the p-side (anode) to the n-side (cathode). When the volt passes through an LED circuit, it encourages electrons to recombine with electron holes, which then releases energy as photons or light. The voltage across the p-n junction must be in the correct direction (forward-biased) in order for an LED to illuminate. A reverse-biased polarity will result in little current and no illumination.

LEDs are considered solid state lighting, which gives them several advantages. They are naturally shock resistant, have significantly long life spans, can withstand quick on/off cycles without damage, and can be formed to crease highly focused illumination.

Extra Features Built into LEDs: Color, Size, Shape, Angle

Sizes of LEDs vary quite significantly depending on the desired end product. Though the standard size is approximately 5 mm in diameter, they can also be made in smaller and larger sizes. LED shapes (determined by cross-section configuration) range from round to square to rectangular to triangular.

Though it might be assumed that creating LEDs with color occurs by modifying the plastic body or package of the LED, colored LEDs are actually constructed by changing the semiconductor material using things such as gallium phosphide, indium gallium nitride, silicon carbide, diamond, or aluminum nitride. They are available in basic colors, including red, amber, orange, green, blue, yellow, and white. Tri-color and bi-color LEDs are created by combining mixing more than one type of lead in the same LED to create more complex colors such as orange-red, pure emerald green, bluish green, near UV, infrared, and far UV.

The viewing angle at which the LED is manufactured can also be customized. The options for LED viewing angle include standard 60° but narrower viewing angles at 15° or less are also possible.