With the growing popularity of flip-chip LED light sources in the market, more people are becoming familiar with this technology. However, many still don’t fully understand what a "flip-chip" actually is. Don't worry—we’ll take it step by step and explain everything clearly.
Traditional LED chips have their p and n electrodes on the same side, which can lead to current crowding and high thermal resistance. The flip-chip structure effectively solves these issues, allowing for higher current density and better uniformity. In addition to material costs, stability and light efficiency are becoming increasingly important in future LED applications. Flip-chip technology is well-suited to meet these demands, especially in high-power LED applications. It’s widely used in small and medium power LEDs, and there are two main types of flip-chip technology. One involves using sapphire-based chips where the substrate is retained for heat dissipation, but current density isn’t significantly improved. The other type removes the substrate entirely, leading to a much higher current density.
The term “flip-chip†comes from its contrast with the traditional gold wire bonding method. In conventional setups, the chip’s electrode faces upward and is connected via gold wires. In a flip-chip, the electrode faces downward, as if the chip has been flipped over—hence the name “flip-chip.â€
As LED technology matures, the industry is continuously pushing for more advanced solutions. Flip-chip LED technology has gained attention in recent years due to its excellent heat dissipation and gold-free design, though it comes with a higher cost. COB (Chip-on-Board) has become a popular stepping stone in the market, offering a balance between performance and affordability.
Today, many major packaging companies are starting to integrate flip-chip COB into their production lines. While it’s not yet the dominant choice, it's an inevitable trend that will gradually replace traditional methods. But why is the traditional approach still so prevalent? Can flip-chip truly replace it? Let’s hear what industry experts have to say.
Flip-chip COB replacing traditional COB is becoming a trend, especially in niche markets. Currently, flip-chip technology isn’t significantly better than traditional COB in terms of brightness, and the price is similar. Market recognition is still limited, and secondary optics for flip-chip aren’t yet perfectly optimized, resulting in a 10–12% lower brightness compared to traditional COB. Even though same-side photoelectric technology can achieve less than 8% loss, challenges remain.
Huang Wenping, director of the same-party photoelectric technology, mentioned that at the same price point, the size of flip-chip LEDs is getting smaller, which reduces brightness. However, when the size is the same, flip-chip LEDs are brighter because they have less light absorption on the front. Overall, the current cost-performance ratio of flip-chip COB isn’t very strong, making it suitable only for a narrow market segment. But it’s definitely a trend, and it will eventually replace traditional COB, becoming even brighter due to its simplified process and structure.
Zheng Haibin, deputy general manager and marketing director of Jiangxi Zhaochi Optoelectronics Co., Ltd., added that some COB products are already mature and cost-effective. Flip-chip COB takes advantage of the chip’s ability to handle higher currents and eliminates the need for gold wires, reducing both material and production costs. This makes it a promising option for the future.
Lei Lining, general manager of Hongli Optoelectronics, believes the current market for flip-chip COB is focused on two ends: low-cost products that don’t require high efficiency, and high-end products in specialized fields, such as limited space lighting or high-power applications requiring high luminous flux and reliability. These areas offer unique opportunities for flip-chip technology.
Xia Xuesong, general manager of Silicon Energy Lighting, also stated that in the medium to long term, flip-chip COB is expected to dominate the market. Zou Yiming, general manager of Shenzhen Xinyueguang, added that with continuous improvements in light output and cost reductions, the future market potential for flip-chip COB is huge.
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