According to a recent report by the physicist organization network, a new manufacturing technology is expected to significantly reduce the production cost of light-emitting diodes (LEDs) and further promote its popularity.
The research by the researchers of OSRAM Opto Semiconductors, a subsidiary of Siemens, successfully produced gallium nitride LED chips on silicon substrates, replacing the more expensive sapphire substrates currently in common use.
Silicon is a standard semiconductor material, which has excellent performance as a large size, low cost, easy processing, and good electrical conductivity. However, the technical difficulty lies in the fact that the thermal expansion coefficients of silicon and gallium nitride are different, and stress is easily generated in the manufacturing process, resulting in uneven thickness or cracking of the film, and thus has not been widely used in the LED industry. Through a special process, the new technology not only avoids the previous cracking, but also makes the new LEDs comparable in stability and brightness to the traditional sapphire-based LEDs, making them ideal for high-power solid-state lighting.
LED is an energy-efficient lighting solution that is considered to be the most promising alternative to traditional light sources. However, LED production costs have been higher than other more mature lighting products so far, so they have not been widely used in daily life. By using new technologies, LED production will be expected to use larger silicon wafers, which will be a significant increase in LED production efficiency.
With this technology, OSRAM has successfully produced a high performance LED wafer with a diameter of 150 mm (6 inches). Researchers have begun to adjust the production process to make 200 mm (8 inch) wafers. This will further increase the number of chips on each substrate and reduce production costs. It is understood that most of the current LED industry is based on 50 mm (2 inches) or 100 mm (4 inches) sapphire substrates. If silicon-based gallium nitride technology can be used, at least 75% of raw material cost can be saved.
At present, this new film-based LED is still in the sample trial stage, and then it will be tested for reliability in a real-life environment. Preliminary experiments have shown that the blue and white silicon-based LEDs produced by this technology can achieve similar performance to the current sapphire substrate products on the market. The first commercial LED products using this technology are expected to be available two years later.
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