LED array packaging brings solderless assembly to solid-state lighting

LED arrays are gaining recognition in the lighting industry. They have the ability to integrate multiple LED light-emitting tubes into a small package, making them more attractive for high-brightness lighting. In addition, as chip-on-board (COB) LEDs, arrays composed of multiple closely spaced LED components can use different LED packages, so the brightness of the light source is higher than that of a larger light source.

The array can be a shared (fried egg) phosphor (like Bridgelux's BXRA):

Alternatively, each LED in the array may have its own phosphor (such as Cree's XLamp MP-L):

Sharp recently joined the LED wars with its Zenigata LED arrays.

These LED arrays offer better performance, but are also more expensive than single-emitter packages. Balancing and matching the LEDs is done at the factory, a difficult process. And, while these arrays are smaller than equivalent single-package LEDs, the array packages are still large, making hand soldering (either for repair or initial manufacturing) a challenge. As a result, connector companies have developed high-temperature plastic LED array holders that use solderless compression contacts. Mouser, for example, makes holders for Bridgelux and Cree arrays and has just introduced holders for Sharp's new Zenigata LEDs, including the 15W, 25W, and 50W Mega Zenigata and the 4W-15W Mini Zenigata.

Molex didn't quote, but by looking up prices on Digikey for the Cree and Bridgelux versions, we can roughly estimate the price to be around $2-3 each in single-volume quantities. These holders also come with an external auxiliary optic, making it an easy way to upgrade not only the LED itself, but also its optics.