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Philips L-Prize A19 LED Lamp: Reverse Engineering & Costing Report

Winner of the DoE L Prize competition to replace 60W incandescent bulb

Featuring 9 blue LED and 9 red LED and remote phosphor

Achieving 940lm for 10W , a color temp. of 2700K with a CRI of 92

Philips Lighting has designed this A19 LED lamp replacement for 60W bulbs in order to win the DoE L Prize competition. Technical specifications were fulfilled: omnidirectional light, luminous Flux of 940 Im at lOW, a correlated color temperature (Ca) of 2700K, and a Color rendering index (CR1) of 92.

This is achieved using 9 blue LEDs and 9 red LEDs assembled on 3 ceramic substrates, combined with 3 remote phosphors to produce the warm color of the bulb.

The retail price of the lamp has decreased since its introduction early 2012, but it is still above the initial objectives. Will it catch up?

System Plus Consulting has performed a full technical and economic analysis of the L-Prize® lamp in order to estimate today manufacturing cost.

This report provides:

  • Detailed photos
  • Material analysis including phosphor
  • LED assembly description
  • Detailed bill-of-material
  • Assembly process flow
  • Manufacturing cost & Selling price estimation

Table of Contents

1. Overview/Introduction

  • Introduction
  • The course of tile analysis

2. Company Profiles

  • Company Profiles
  • Component Characteristics

3. Physical Analysis

  • Packaging
  • Disassembly
  • Remote Phosphor
  • lisassembly
  • Connector Board
  • LED Substrate
  • LED Substrate-Top Side - Global View
  • LEb Substrate-Bottom Side - Global View
  • LEI Substrate-Cross-Section
  • LXML-PBO2-0080
  • LXML-Pl)O1-0040
  • Warm color
  • Main Board

3. BOM Cost

  • Assessing the BOM
  • Estimation of the cost of the PCB
  • Estimation of the cost of the Electronic Boards
  • Estimation of the cost of the Housing
  • Material cost breakdown

4. Added Value Cost

  • Assessing the Added Value (AV) cost
  • Main Board Manufacturing Flow
  • Main Board Hourly Rates
  • etails of the Main Board AV Cost
  • Details of the Connector Board AV Cost
  • Details of the LED Substrate Board AV Cost
  • Details of the LED Lamp Board AV Cost

5. Estimation of the selling price

  • Manufacturing Cost Breakdown
  • Estimation of the Selling Price
  • Functional Breakdown

6. Conclusion

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