New LED Substrate "ZeroGap"

"What is lighting of the future?"
LEDs are the first thing that spring to mind thanks to their high efficiency and almost indefinite
service life.

The all important factor behind the reliability of LED lights is LED cooling. The heat from power dissipation flows from the LED chip through the LED component, through the circuit board to the luminaire housing, which usually serves as a heat sink.

An often critical factor is the printed circuit board since the heat must flow through an insulating layer, which is not only insulated electrically but also thermally.

Choosing the correct printed circuit board material is particularly important

•  when using high-power LEDs
•  with small dimensions especially
•  at high ambient temperatures

The most commonly used printed circuit board takes the form of IMS (insulated metal substrate), which is a single-sided circuit on an aluminium substrate. The aluminium is separated from the conductive pattern by thin insulation, shown in white in the image below.

Principle of IMS PCBs (insulated metal substrate)


Principle of IMS PCBs
(insulated metal substrate)

In the past, material manufacturers have done everything possible to improve the cooling effect.
Most developments were aimed at increasing thermal conductivity of the insulating layer material.


The ANDUS solutionNeues LED-Substrat ZeroGap
 
ANDUS has now successfully implemented a different approach. Rather than improving thermal conductivity, the layer thickness was greatly reduced. After all, we have nearly reached our limits when it comes to material improvement; as far as layer thickness is concerned, however, we still have some way to go.


Thermal conduction through ZeroGap insulation compared
with conventional IMS material

Thermal conduction through ZeroGap insulation compared with conventional IMS material

The goal was an almost non-existent insulation gap between the conductive pattern and aluminium. Hence the name ZeroGap. At the same time, the electrical insulation provided is sufficiently high at
500 volts. With a final thickness of only four microns, the new material boasts insulation that is thinner by more than one order of magnitude compared with conventional IMS substrates. It therefore surpasses even the best material of the most well-known manufacturer in the field of IMS substrates.

ZeroGap is able to cool today's high-performance LEDs with their miniscule designs, even under adverse ambient conditions. Applications include, for example, UV illumination in the chip, adhesives and printing industry, special lights for terrain lighting, tunnel lighting or special sensor applications.

UV illumination in the chip, adhesives and printing industry

UV illumination in the chip, adhesives and printing industry Tunnel lighting

Tunnel lighting

Special lights for
terrain lighting

Special lights for terrain lighting Stage lighting

Stage lighting

Power electronics

Power electronics Special sensor applications

Special sensor applications