OSRAM OSTAR Automotive Headlamp Pro
 

OSRAM OSTAR Automotive Headlamp Pro

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igh performance Vertical Thin Film with Vias (VTFV) dies in a new and more efficient packaging for harsh environment. ...

igh performance Vertical Thin Film with Vias (VTFV) dies in a new and more efficient packaging for harsh environment.


The LE UW U1A4, that belongs to OSTAR Headlamp Pro family, shows a breakdown voltage of 13.3V for a current of 1A (at 85°C) and delivers up to 1000 lumens at 5600K in a “20mm x 20mm” package. These performance are obtained due to a complex packaging and assembly process, completely described in this report.

Compared with the first generation of Osram’s packaged LED for exterior automotive headlamps, the new OSTAR Headlamp Pro comes with an enhanced design to increase the corrosion robustness and, for the first time, with a remote ceramic phosphor to increase efficiency.

This reverse costing report provides an estimation of the production cost of the LE UW U1A4. It describes the overall manufacturing process and highlights key points of innovation developed by OSRAM.

More information on that report at http://www.i-micronews.com/reports/OSRAM-OSTAR-Automotive-Headlamp-Pro/14/451/

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OSRAM OSTAR Automotive Headlamp Pro OSRAM OSTAR Automotive Headlamp Pro Presentation Transcript

  • DISCLAIMER : System Plus Consulting provides cost studies based on its knowledge of the manufacturing and selling prices of electronic components and systems. The given values are realistic estimates which do not bind System Plus Consulting nor the manufacturers quoted in the report. System Plus Consulting is in no case responsible for the consequences related to the use which is made of the contents of this report. The quoted trademarks are property of their owners. © 2014 by SYSTEM PLUS CONSULTING, all rights reserved. 1 Electronic Costing & Technology Experts www.systemplus.fr 21 rue la Nouë Bras de Fer 44200 Nantes – France Phone : +33 (0) 240 180 916 email : info@systemplus.fr June 2014 – Version 1 – Written by Sylvain Hallereau
  • Osram Opto LE UV U1A4 01 7Q6REB - LED Array Return to TOC © 2014 by SYSTEM PLUS CONSULTING, all rights reserved. 2 Glossary 1. Overview / Introduction 4 – Executive Summary – Comparison of LEDS – Reverse Costing Methodology 2. Companies Profile 9 – Osram Opto Profile 3. LE UV U1A4 LED headlamp Characteristics 11 – LE UV U1A4 01 7Q6REB Characteristics 4. Physical Analysis 15 – Physical Analysis Methodology – Package Views & Dimensions – Package Opening – X-Ray – Package Cross-Section – IMS Substrate – AlN Substrate – Phosphor – LED Assembly – Package Characteristics – LED Views & Dimensions – LED Cross-Section – Cathode – Anode – Dielectric Layers – Epitaxy – LED Thickness – LED Characteristics – OSTAR Headlamp Pro Comparison 5. Manufacturing Process Flow 55 – Global Overview – LED Fabrication Unit – LED Process Flow – Package Fabrication Unit – Package Process Flow 6. Cost Analysis 67 – Synthesis of the cost analysis – Main steps of economic analysis – Yields Hypotheses – Epitaxy Step – LED Front-End Cost – LED Wafer Cost – LED Cost per process steps – LED Equipment Cost per Family – LED Material Cost per Family – Back-End : Probe and dicing Cost – Packaging Cost – Final Assembly Cost – Component Cost & Price 7.Estimated Manufacturer Price Analysis 93 Contact 99
  • Osram Opto LE UV U1A4 01 7Q6REB - LED Array Return to TOC © 2014 by SYSTEM PLUS CONSULTING, all rights reserved. 3 • Package is analyzed and measured. • Package is opened in order to identify the elements constituting it. • Cross-section are realized to get overall package data : dimensions, main characteristics. • The LED is analyzed and measured. • SEM photographs to measure the LED dimensions. • Cross-section are realized to get overall LED data : dimensions, main characteristics. • An analysis of the technologies and of the materials used is performed.
  • Osram Opto LE UV U1A4 01 7Q6REB - LED Array Return to TOC © 2014 by SYSTEM PLUS CONSULTING, all rights reserved. 4 Cathode contacts Anode contactsFour LEDs in series + protection diode Aluminium heat-spreader with the PCB form an IMS (Insulated Metal Substrate) Cathode bond wire (covered) Anode bond wire (covered) Ceramic substrate Si dam Optical tilted view : package Optical top view : package
  • Osram Opto LE UV U1A4 01 7Q6REB - LED Array Return to TOC © 2014 by SYSTEM PLUS CONSULTING, all rights reserved. 5 Remote phosphor plate AlN ceramic substrate Ge LED cathode Dam black silicone thinned Al heat spreader white silicone AlN ceramic substrate Dam Optical view : cross section of the package. SEM view : cross section of the package. Optical view : detail
  • Osram Opto LE UV U1A4 01 7Q6REB - LED Array Return to TOC © 2014 by SYSTEM PLUS CONSULTING, all rights reserved. 6
  • Osram Opto LE UV U1A4 01 7Q6REB - LED Array Return to TOC © 2014 by SYSTEM PLUS CONSULTING, all rights reserved. 7 • The front-end cost ranges from $xx to $xx according to yield variations. • The high cost of the wafer explain the portion of the manufacturing cost is due to yield losses in the cost. • The new equipment explain the portion of the manufacturing cost is due to the equipment at xx%. • The manufacturing yield is between xx% and xx% in 2013
  • Osram Opto LE UV U1A4 01 7Q6REB - LED Array Return to TOC © 2014 by SYSTEM PLUS CONSULTING, all rights reserved. 8
  • Osram Opto LE UV U1A4 01 7Q6REB - LED Array Return to TOC © 2014 by SYSTEM PLUS CONSULTING, all rights reserved. 9 Reverse costing analysis represents the best cost/price evaluation given the publically available data, and estimates completed by industry experts. Given the hypothesis presented in this analysis, the major sources of correction would lead to a +/- 10% correction on the manufacturing cost (if all parameters are cumulated). These results are open for discussion. We can reevaluate this circuit with your information. Please contact us: European & USA Office • Yole Développement Headquarter, France: David Jourdan, Sales Coordination & Customer Service, Tel: +33 472 83 01 90, Email: jourdan@yole.fr Japan Office • For custom research: Yutaka Katano, General Manager, Yole Japan & President, Yole K.K. Phone: (81) 362 693 457 - Cell : (81) 80 3440 6466 - Fax: (81) 362 693 448 - Email: katano@yole.fr • For reports business: Takashi Onozawa, Sales Asia & General Manager, Yole K.K. Email: onozawa@yole.fr Korea Office • Hailey Yang, Business Development Manager, Phone : (82) 2 2010 883 - Cell: (82) 10 4097 5810 - Fax: (82) 2 2010 8899 – Email: yang@yole.fr