Category Archives: LED Manufacturing

The LIGHTFAIR International (LFI) 2015 Call for Speakers opens in a global invitation seeking responses from top lighting and design practitioners looking to participate in the world’s largest annual architectural and commercial lighting trade show and conference in New York May 3-7, 2015.

The 2015 LIGHTFAIR Conference champions Integrated Design as the central theme linking all courses, workshops and seminars.  Sessions highlight how experienced project contributors collaborate to optimize environments.  Speakers are invited to share how elements such as: technology, tools, research, problem solving and inspiration contribute to the overall integrated design process.

With integrated design as its platform, LIGHTFAIR International 2015 offers a vibrant atmosphere where diverse disciplines come together to present, discuss, debate, exchange and explore best practices and emerging concepts to enable the creation of socially responsible, effective, pleasing environments.

Experts from various industries such as architecture, design, engineering, exterior and roadway, facility management, government, healthcare, hospitality, alternative energy including solar power, transportation and more are encouraged to pursue presentation opportunities at LFI 2015.

The LIGHTFAIR 2015 Conference provides knowledge and perspectives on how a collaborative, multidisciplinary approach can improve design outcomes for the betterment of the human experience through four Focus Areas:

Inspiration – Rule-breakers, trailblazers and visionaries dramatically influence our industry. Sessions should provide a synthesis of factors from inside and outside of the established lighting community, including artists, industrial designers, scientists and medical professionals.

Applications Research – Scientific analysis related to how we interact with the environment around us informs design. Example topics might include human factors studies, the physiological impact of light and case studies.

Technology and Tools – Innovative lighting equipment, software, studies and legislation are introduced every year. Using these elements to shape the design, or enhance and challenge the collaborative process, builds a stronger solution. Example topics might include sources, luminaires, components, controls, alternative energy sources, daylighting, technology, codes and standards.

Methodology – Processes using collaborative, interdisciplinary approaches can result in more effective project solutions. Working together and exploring diverse methods can streamline these processes. Example topics might include integrated design and coordination strategies, the role of mock-ups, procurement and how technology can improve and enhance the communication process and solve problems. Case studies may be helpful in showcasing strategies.

Courses range in level (general, foundational, intermediate and advanced) and length (60-minute seminars, 90-minute seminars, 3-hour workshops, 1-day courses and 2-day courses).

Seoul Semiconductor Co., Ltd., an LED manufacturer has announced that the company was ranked as number four in the global rankings for Packaged LED Revenue in 2013 according to the market research firm IHS Technology. This is a step up from the 2012 ranking of number five global LED manufacturer despite any internal captive revenue.

One of the most important factors of Seoul Semiconductor’s consistent growth in the global LED market is based upon its established patent portfolio that consists of more than 10,000 patents. The company invests approximately 10% of its sales revenue each year into LED product research and development. Seoul Semiconductor was also the sole semiconductor company that only manufactures LED components to be selected in the 2012 and 2013 Semiconductor Manufacturing Patent Power Ranking by the Institute of Electrical and Electronics Engineers (IEEE).

As Seoul Semiconductor has manufactured LED technology for more than 20 years, the company continues to secure its place in the global LED market with continuous improvements and advancements in its LED product portfolio. In 2006, Seoul Semiconductor launched the revolutionary direct AC LED technology ‘Acrich’ which can be driven directly from AC without an AC-DC converter. After that, Seoul Semiconductor launched the nPola LED technology to boost brightness 5-10 times that of a conventional LED. Recently in June, Seoul Semiconductor launched the next generation of smart lighting with ‘Acrich3’ IC technology.

From the early 2000s when the LED lighting market was not fully developed, Seoul Semiconductor strengthened its sales teams and global marketing strategy. The company secured its business competence by providing high-quality LED products through 50 overseas sales offices including five production sites in Europe, North America and China.

Jung-Hoon Lee, CEO of Seoul Semiconductor, notes that “Because Seoul Semiconductor has no captive market and does not produce or sell LED lighting finished goods all LED lighting manufacturers in the lighting market, which is estimated to grow to $150 Billion, are potential Seoul Semiconductor customers.”

In 2013, Apple completely saved the sapphire industry. This year, in 2014, Apple could transform this industry. Will the revolution happen?

All these results are part of Yole’s report: analysts provide an updated analysis of new consumer electronic applications (smart watches, camera lens and fingerprint …). They also highlight the GTAT/Apple partnership: display cover, manufacturing cost modeling, supply chain capacity analysis, yield impacts and paths to cost reduction.

This new report also provides an analysis of Apple sapphire related patents as well as recent sapphire substrates price trends and forecast and updated supply and demand analysis.

Screen Shot 2014-08-05 at 5.19.50 PM

The sapphire industry recently ended a long period of depressed pricing and achieved US$936 million in revenue for wafer products in 2013. Recovery was helped by an increase in LED demand due to accelerating adoption in general lighting and a resilient LCD backlight market. But the saving grace was new consumer electronic (CE) applications: camera lens and fingerprint reader covers, mostly driven by Apple in 2013. Adoption at other vendors is progressing at a slower pace than anticipated in 2014. LG even reversed the trend with its

flagship cellphone: its G2 model featured a sapphire lens cover but the G3 uses glass. However, Yole’s analysts are optimistic for the mid-term with adoption increasing in Taiwan and China. In addition, new applications such as LED fi laments could further increase sapphire consumption.

After almost 2 years of losses, the price of sapphire cores increased more than 50% in 2013. In Q2-2014, tier-1 sapphire vendors were finally selling at breakeven prices. However, Yole expects that prices will decrease again in Q4.

In November 2013, GTAT and Apple announced partnership to set up a large sapphire manufacturing plant in Mesa, Arizona. Yole’s thorough analysis concluded that the objective of the investment is to produce sapphire display covers for cell phones.

“Apple plans to introduce both a 4.7” and a 5.5” model this year”, announces Dr Eric Virey, Senior Analyst at Yole. “We believe that prices for the sapphire cover have been agreed upon and locked by contract, based on yield assumptions reflecting reasonable expectations from all partners. We used yield assumptions derived from other Tier-1 sapphire makers in the LED industry to model the cost for both sizes. For the finished 4.7” display, we estimate a cost of $16, including $6.7 at the slab (material) level. On the longer term, we see a path for <$13”, he adds. Under those assumptions, Yole also estimates that the supply chain could deliver more than 5 million display covers per month.

But the challenges in term of ramp up execution are unprecedented in the industry. Recent checks point to bottlenecks at various levels of the process with lower than anticipated crystal growth and finishing yields. As of August 2nd 2014, Yole estimates that the supply chain capacity is currently ~2.1 million units per month. If yields don’t improve rapidly, Apple walking away from sapphire is still a possible scenario. The company believes that moderate quantities of supplemental material is currently being sourced from GTAT equipment customers in China. But even if all partners manage to improve yields rapidly, Yole’s analysis still excludes the possibility that sapphire can be used on all models of the new 2014 iPhone. However, Yole still expects that at least one model (SKU) will be offered in 2014 with a sapphire cover. This would allow Apple to plant a stick on the ground and make a statement. Scarcity could even be a good marketing tool providing it doesn’t last too long and that the supply chain catches up quickly. Releasing at least one SKU with sapphire would allow Apple to gage customer response and decide if it should adopt sapphire on more models, plan for more investment in the supply chain or simply walk away.

For the procurements of wafers for camera lens and fingerprint reader covers, Apple is now taking a back seat and letting their Chinese finishing contractors handle the sourcing. This resulted in accelerated commoditization (strong price pressure) and shifted large volumes toward Chinese sapphire vendors. Combined with current high levels of inventories, this has significantly impacted established vendors since the beginning of the year.

Procurement has started for the iWatch and is so far mostly benefiting Chinese vendors as well. Various designs have surfaced including one with a curved display (“2.5D design”) which would be more expensive to produce.”In any case, we expect that Apple will keep tapping into the existing supply chain and let GTAT focus on display covers”, says Eric Virey.

Yole’s report, August 2014 update, includes a thorough analysis of the GTAT/Apple deal. It explains key hypothesis of our cost model and provides thorough yield sensitivity analysis for cost and capacity. Cost, capacity and revenue models are presented for both 4.7” and 5.5” displays.

Cambridge Nanotherm, a producer of semiconductor heatsink technology, today announced that it has appointed semiconductor industry veteran Ralph Weir as its CEO. This follows just a few months on from news of the initiation of its first production line, allowing the company to roll out its advanced nano-ceramic heat dissipation technology at high volumes to meet the growing needs of LED makers. Cambridge Nanotherm today also announces the appointment of a new Business Development Director, Andrew Duncan, as well as ISO 9000 accreditation of its production line.

Ralph Weir has been appointed to ensure a smooth transition to mass production and to drive the next phase of Cambridge Nanotherm’s global growth. Ralph brings with him unrivalled experience and relationships within the relevant markets, and a strong track record in leading advanced technology teams in a variety of companies, including Polar OLED, Actiri, Phase Vision, Mirics and Elixent. Dr. Pavel Shashkov, who has held the CEO role since the company was founded, is taking the role of Chief Technology Officer.

Cambridge Nanotherm’s products are based on a its patented dielectric nano-ceramic coating with extraordinarily high thermal conductivity. Cambridge Nanotherm’s embeds its game-changing technology in Aluminium-backed PCBs using standard processes, or places it over or around semiconductors. The material currently wicks away heat at two to three times the rate of competing solutions, while still being four to ten times thinner. This allows producers of various semiconductor devices to produce radically cooler and more efficient devices, or increase the density of their products, allowing e.g. brighter LEDs or more computational power within a given space.

“With our announcement that we’ve been accredited to the ISO 9000 quality standard, and the ramping up of our line producing custom metal-backed PCBs, Cambridge Nanotherm is a company currently going from strength-to-strength,” commented Ralph Weir, new CEO. “We’re posing a solution to one of the biggest problems facing the semiconductor world today; heat dissipation, and doing so with a technology that is far more advanced than that of the competition. Given these facts, and the strong financial backing from Venture Capital firm Enso ventures, I’m joining this ambitious company at a hugely exciting time. I look forward to helping Cambridge Nanotherm undertake this critically important next step.”

Joining alongside Weir as Business Development Director is Andrew Duncan. Duncan has a successful history with a variety of specialised Ceramics companies, including Morgan Advanced Ceramics, (as technical manager for Metallised Products), and CeramTec, (as Technical Sales Manager). Andrew is tasked with expanding Cambridge Nanotherm’s already-considerable customer base and capitalising on the company’s early momentum.

TriQuint Semiconductor, Inc., a RF solutions supplier and technology innovator, announced that it is the first gallium nitride (GaN) RF chip manufacturer to achieve Manufacturing Readiness Level (MRL) 9. This achievement means TriQuint’s GaN manufacturing processes have met full performance, cost and capacity goals, and that the company has the capability in place to support full rate production.

To benchmark MRL 9, TriQuint applied the U.S. Air Force Research Laboratory’s rigorous manufacturing readiness assessment tool and criteria to its high frequency, high power GaN production line. TriQuint’s ongoing development of GaN-based devices is leading to smaller, more efficient power amplifiers, typically used for military radar and electronic warfare programs as well as commercial wireless communications and infrastructure.

“TriQuint recently completed its Defense Production Act Title III GaN on silicon carbide (SiC) program and now we’ve proven that we provide the GaN maturity needed to support full-rate production programs,” said Vice President and General Manager James Klein, Infrastructure and Defense Products. “This has been a great team effort utilizing our partnerships across the industry including US DoD, domestic and international customers, and a great supply base.”

Key to the company’s assessment, TriQuint has shipped more than 170,000 0.25 um GaN power amplifier devices in support of an ongoing international radar production program. During phased array radar field testing, approximately 15,000 devices have accumulated more than 3.67 million device hours, with no reported device failures. TriQuint continues to demonstrate industry-leading reliability with a mean time to failure (MTTF) of greater than 70 million hours at 200 degrees Celsius, substantially greater than the industry standard of 1 million hours MTTF.

As an established GaN provider for domestic and international defense programs, TriQuint explored the potential of GaN beginning in 1999, and released its first GaN on silicon carbide (SiC) production process in 2008. Since that point, the company has continued to make significant investments towards maturing the technology. Today, GaN wafers are manufactured with yields that match our conventional GaAs technologies. TriQuint continues to provide record-setting GaN circuit reliability and compact, high efficiency products, paving the way for more robust performance, lower maintenance and longer operational lifetimes. TriQuint is also accredited by the Department of Defense as a Microelectronics Trusted Source (Category 1A) for its foundry; post-processing; packaging and assembly; and RF test services.

The Department of Defense’s Manufacturing Readiness Assessment (MRA) ensures that manufacturing, production and quality assurance can meet operational mission needs. This MRA tool assesses science and technology companies on criteria that provide guidance about the maturity and risk of a given technology – reviewing the industrial base readiness; technology development; and quality and manufacturing management. This process ensures that the product or system transitions successfully from the factory to the field, providing the best value for the customer. TriQuint demonstrated that its manufacturing processes met full performance, cost and capacity goals, with the capability in place to support full rate production.

China’s massive investments in light-emitting diode (LED) manufacturing capacity are paying off, with a Chinese company entering the top ranks of the global market for the first time ever, according to IHS Technology.

China’s MLS Electronics Co. Ltd. in 2013 rose to the No. 10 rank in the worldwide market for packaged LEDs, up from 14th place in 2012. With the other top 10 players based in South Korea, Japan, the United States, Germany and Taiwan, as presented in the attached figure, this represents a first for China’s burgeoning LED industry.

2014-06-18_LED_Rank_Final

“Since 2011, most of the new LED production capacity that has been added worldwide has occurred in China,” said Jamie Fox, principal LED analyst for IHS. “Because of this, it was inevitable that Chinese companies eventually would penetrate the ranks of the top 10 LED suppliers. MLS was first to join the global elite, having established itself as the clear leader in the Chinese market by capitalizing on strong domestic demand. For the major suppliers, MLS’s ascent into the market’s upper ranks represents a clear signal that Chinese firms soon will become major competitors in the global LED business.”

These findings come from the IHS LED Intelligence Service.

China’s LED market lights up

MLS is one of many Chinese LED suppliers that have sprung up amid the surge in production. However, the other firms do not even rank among the top 20 global suppliers. China’s LED supply base is massive and highly fragmented, with thousands of small manufacturers located across the country.

“Despite leading the domestic market, MLS accounted for less than 10 percent of Chinese LED revenue in 2013,” said Alice Tao, China LED analyst at IHS. “The next five largest LED suppliers in China represented only about 20 percent of the market.”

With the rise of LED manufacturing capacity in China, concerns have risen relating to overcapacity. Some of the equipment purchased for metal-organic chemical vapor deposition (MOCVD) manufacturing—the most important process step in LED production—is now sitting idle in China. Observers have fretted that the overcapacity could result in the shutdown of some Chinese suppliers.

However, only a few of the smaller Chinese vendors so far have closed their LED operations. Most of the top companies remain active in the market, with some posting strong profit margins.

An insular market goes global

MLS and the smaller Chinese suppliers mostly compete among themselves for a share of the large domestic LED market. The international portion of sales for these companies is very small.

At the same, the extremely low prices in the Chinese market make the country inaccessible to overseas suppliers. Because of this, foreign LED makers don’t encounter Chinese competitors very often.

But that situation will change rapidly. IHS expects the LED revenues of Chinese vendors to grow steadily over time, as the country’s economy continues to grow strongly. Because of this, Chinese LED suppliers will begin to sell more internationally and come into competition with foreign rivals.

Barriers to entry

Both intellectual property and quality are concerns for international customers that are considering Chinese suppliers.

However, several factors suggest these concerns could be alleviated over time. These factors include patent expirations, China’s established history in other industries, the sheer volume of manufacturing capacity in the country and the fact that many LED lamps are assembled in the nation.

Top-tier LED suppliers such as Nichia, Osram, Lumileds and Cree so far have seen only a small impact from Chinese vendors on their sales. This is especially true in the market for general lighting in regions such as Europe and the Americas. Such will not necessarily be the case by the end of the decade.

For instance, MLS has started 2014 on a strong note, and may have even ranked among the IHS top 10 LED suppliers in the first quarter.

One out of every four dollars spent worldwide on light-emitting diode (LED) drivers in 2013 was used for lighting applications, illustrating the growing importance of illumination in the LED business, according to IHS Technology.

LED driver revenues from lighting applications last year totaled $305 million, representing 25 percent of the total driver market of $1.2 billion, as presented in the attached figure. The LED lighting market will continue to boom in the coming years, causing revenue for associated drivers to nearly triple to $893 million in 2019. This will amount to 43 percent of the $2.1 billion LED driver market.

2014-06-19_LED_Driver

“Lighting represents the fastest-growing segment of the LED market, and is accounting for a larger share of market revenue—as well as of overall driver sales,” said Jamie Fox, principal LED analyst for IHS.

The lighting segment mainly consists of lamps and luminaries, with flashlights, architectural illumination and other applications representing a smaller share of the market. Lamps accounted for most of the lighting units shipped in 2013, and for 50 percent—or $151 million—of the revenue for all lighting ICs. This share is set to increase.

The information in this release is derived from the report entitled “LED Driver ICs — World” from the Lighting & LEDs service at IHS.

Driving to growth

An LED driver is an integrated circuit (IC) that manages and controls the electrical current for an LED.

LED driver ICs play an important role in energy savings and are used to support most high-brightness LEDs. Drivers are regarded as an important, if not essential, feature in high-quality LED lighting products.

Beyond the lighting segment, there are also significant sales of driver ICs to diverse applications such as signage, mobile handsets, TVs, notebooks, monitors and tablets, as well as automotive applications.

Price pressure lightens up

LED drivers aren’t subject to the same brutal price erosion that’s impacting the LED market itself. As a result, LED driver revenue will rise by double-digit percentages in 2014, 2015 and 2016.

Furthermore, unit sales of dimmable LED lamps are outgrowing those of non-dimmable lamps. The average price of drivers for non-dimmable lamps is much higher than dimmable lamps, helping maintain strong revenue growth.

Texas Instruments drives to the top

Texas Instruments maintained its position as the leading supplier of LED driver ICs in 2013, followed by STMicroelectronics.

In the signage segment of the market, Taiwan’s Macroblock remained the leader. Meanwhile, Western semiconductor giants played prominent roles in other segments, including companies such as On Semiconductor, Maxim, NXP, Skyworks, ams and Power Integrations.

While suppliers overall focus on different markets, most of the companies that are expected to continue growing will remain directed toward a lighting market that already accounts for a quarter of the total business, and will continue to grow as LED lamp sales increase rapidly during the next few years.

Crystal IS, a developer of high-performance ultraviolet (UVC) LEDs, this week announced availability of Optan. The first commercial semiconductor based on native Aluminum Nitride (AIN) substrates, Optan provides a unique technology platform for increased detection sensitivity, essential for analytical and life sciences instrumentation—from monitoring of chemicals in pharma manufacturing to drinking water analysis.

The Optan product is a breakthrough for design engineers looking to overcome limitations associated with traditional UV lamps, including deuterium and xenon flash lamps. As an enabling technology, Optan allows developers to fully exploit the power of UV-based technology to improve productivity, increase accuracy and create greater flexibility in product designs.

“This is an exciting time for Crystal IS and an achievement for the semiconductor industry as a whole,” said Larry Felton, CEO of Crystal IS. “Optan will help instrument manufacturers build smaller, more powerful tools and products with a lower overall system cost. We look forward to the scientific and environmental contributions their new products will provide.”

The superior light output and spectral quality of the Optan UVC LED technology, made possible by the unique, low defect AIN substrate, delivers best-in-class reliability, and longer lifetimes, a game changer for life sciences and analytical instrumentation, including environmental monitoring.

Immediate use cases include:

  • HPLC (high-performance liquid chromatography), a powerful tool in analysis for detecting chemicals and compounds in life sciences.
  • Spectrometers, used in multiple applications in testing and analysis across biotech, life sciences and environmental monitoring.
  • Water quality monitoring sensors, becoming increasingly important for detecting chemicals in water from fracking, water security and the use of treated wastewater.

 

The Optan LEDs are currently available in peak wavelengths from 250nm to 280nm and power bins from 0.5mW to 2mW, ideal for spectroscopic applications because of their high spectral quality and reliability. Full availability for all bins under 3mW is anticipated for next quarter with higher power bins (3-4mW) available this Fall, 2014.

Dow Corning today announced that its recently launched Dow Corning® MS-2002 Moldable White Reflector Silicone was the winner of the Non-Luminous Components, Specialty Hardware, Shades and Solar category at the 2014 LIGHTFAIR International Innovation Awards. This marks the third time in two years that Dow Corning’s Moldable Silicone product technology has garnered top recognition during LIGHTFAIR International’s (LFI) annual awards.

Held each year during LFI, the world’s largest annual architectural and commercial lighting trade show and conference, the award competition recognizes the best lighting-related applications and designs introduced over the past year. Judged by an independent panel of lighting industry professionals, MS-2002 Moldable White Reflector Silicone beat out 13 competitors to win its category.

“Cutting-edge LED design begin with cutting-edge LED materials, and MS-2002 Moldable White Reflector Silicone is helping to redefine the performance boundaries for next-generation LED lighting,” said Hugo da Silva, global industry director, LED Lighting at Dow Corning. “This new highly moldable reflective material is already making a clear impact on the LED industry, as demonstrated by its top spot among this year’s LFI awards. MS-2002 Silicone’s impact is further evident from the positive customer feedback on its exceptional performance and durability in a wide array of demanding, high-heat LED applications.”

Launched in late 2013, MS-2002 Silicone is a bright white material that extends its excellent photo-thermal stability and high-moldability to the reflective elements of LED lamp and luminaire applications. It targets reflectivity as high as 98 percent to help further boost light output from LED devices, improve overall energy efficiency and prolong device reliability. The new technology also provides excellent moldability to enable complex shapes, micro optical features, multifunctional parts and even undercuts once difficult to achieve with plastics or glass.

MS-2002 Moldable White Reflector Silicone can be easily overmolded onto transparent silicones and enables such LED concepts as mixing chambers for superior light output vs. competitive materials. The material offers outstanding mechanical, thermal and optical stability at temperatures exceeding 150° C where conventional LED materials, such as epoxies, polycarbonates and acrylics often yellow or degrade. This is critical as LED sources are increasingly expected to deliver more intense white light from comparatively smaller package sizes, and as customers seek smaller designs with higher luminous flux, which also drives up temperatures at the device level.

“Receiving this LFI award is a true honor,” da Silva added. “Not only does it recognize our contribution to an increasingly important market, but also spotlights our commitment to our LED customers and the industry as a whole.”

This year’s award for MS-2002 Silicone follows top recognitions for Dow Corning at last year’s LIGHTFAIR show.

LIGHTFAIR International is the world’s largest annual architectural and commercial lighting trade show and conference. Held recently at the Las Vegas Convention Center on June 3-5, the event sets the global stage each year for lighting, design and technology innovation.

Crystal IS, a developer of the most effective UVC LEDs, today announced the appointment of John Gartner as its first vice president of operations. Gartner brings more than thirty years of experience in manufacturing and engineering, including establishing and growing manufacturing operations for clean and reliable energy solutions. His expertise and experience will help transition Crystal IS from R&D to a manufacturing company poised to become the market leader in UVC LEDs for life sciences, environmental monitoring and disinfection.

“It is clear that Crystal IS has committed to moving from R&D to commercial product development,” said John Gartner, vice president of operations, Crystal IS. “I’m thrilled to be part of the team leading the company in this exciting time.”

In conjunction with the addition of Gartner, Crystal IS continues to expand the Green Island facility preparing it for full scale production and shipping of soon to be announced Optan product with the addition of:

  • a raw material furnace as well as three additional furnaces and a chiller to double manufacturing capacity
  • a new lab and production equipment for fine wafer polishing
  • moving fabrication in-house to the AK Fuji facility
  • twenty-three percent employee growth across the organization in areas including application engineering, quality, customer support and product marketing

“Our move from R&D to commercial production was inevitable,” said Larry Felton, chief executive officer. “Appointing John Gartner as our first vice president of operations and expanding our manufacturing capacity demonstrates our commitment to commercializing our superior technology and getting our breakthrough products to customers.”