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LED

The Battle of the LED Substrates Heats Up

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LEDs

Soraa, Bridgelux, and Osram battle for the LED substrate crown.

A four-way LED substrate battle is shaping up among sapphire, silicon carbide, silicon, and gallium nitride materials.

The prize is much cheaper LED chips and lighting products.

Soraa’s recent unstealthing added gallium nitride (GaN) to the active contender list with its GaN-on-GaN device. On the silicon (Si) front, Osram Opto CTO Ulrich Steegmueller presented the company’s Si research at a recent lighting event. Bridgelux, also researching silicon, raised $25 million in funding from China.

There are some dark horses, including glass, germanium, and aluminum nitride (AlN).

Nitride Solutions of Wichita Kansas closed an oversubscribed $2.5 million round A this month for AlN substrates, with an ultraviolet market emphasis.

High brightness LEDs (other than red) are derivatives of gallium nitride. As with semiconductors, generally, you want to build on a stable substrate with an accurate crystal lattice, but gallium nitride is unstable and defect-ridden. The stable alternatives have a lattice spacing mismatch with the GaN and the result is shattered wafers and efficiency loss. A variety of coping techniques have evolved, such as buffer layers. (For a readable backgrounder on the topic, see here.)

The status quo is sapphire. But the cost of making LEDs out of synthetic gemstones has drawn in the other contenders.

  • Sapphire: the defender. Users are almost everyone but Cree; Lattice mismatch: 13 percent; Advantage: Stable, mismatch well researched; Disadvantage: Too expensive for what you get; Bottom Line: Will never meet DOE’s 20X cost reduction goal.
  • Silicon Carbide: the Macintosh of substrates. Users are mainly Cree; Lattice mismatch: 3.5 percent; Advantage: Very stable. Low mismatch aided by cancelling thermal mismatch, highest thermal conductivity; Disadvantage: Priciest, almost proprietary; you may have to buy it from your toughest competitor; Bottom Line: Relatively less costly and difficult if you’re Cree, costlier and harder if you’re anyone else. Cree was a silicon carbide company before becoming an LED company.
  • Silicon: Users — Research maturing in Osram Opto, Bridgelux, China; Lattice mismatch:17 percent (plus a 56 percent additive thermal mismatch); Advantages: 80 percent substrate cost reduction potential, ubiquitous, big wafers; Disadvantages: Lattice and thermal expansion mismatches from hell.
  • Gallium Nitride: Users: Soraa; Lattice mismatch: 0 percent; Advantage: Lattice and thermal match from heaven, homogeneous material allows higher drive level by tuning the GaN for reduced droop; Disadvantage: Unstable, defect-ridden; Bottom line: Analogous to Cree and silicon carbide, relatively less costly and less difficult if you’re Shuji Nakamura, Steve DenBaars, and Jim Speck, much worse if you’re anybody else.

Soraa is performing a bit of a head fake by not selling LEDs, shipping only a finished MR16 halogen reflector where their compact die is able to win with superior beam concentration. However, that is essentially how all LEDs compete with high pressure sodium lamps to this day.

While we shouldn’t get ahead of ourselves, new substrates could turn some non-adapting companies into stranded whales. Cree may have a particular hazard here, with a unique, almost emotional, commitment to silicon carbide. On the principle that any new substrate will only be adopted if it has a cost or performance advantage, the battle of the substrates will, in the end, only accelerate and enhance the inevitable transition to solid-state lighting.

By: DOUG WIDNEY
Source: http://www.greentechmedia.com/articles/read/the-battle-of-the-led-substrates-heats-up/

Lemnis unwraps LED bulb under $5

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The no-frills Pharox 200 Blu from Lemnis Lighting, priced at $4.95, is designed to tempt consumers to try out LED lighting. (Credit: Lemnis Lighting)

Lemnis Lighting is taking a foot-in-the-door approach to LED lightbulbs.

The startup company today announced a new line of bulbs, priced at $4.95 and $6.95, respectively, aimed at getting consumers to try out LEDs for general lighting. The bulbs, though, have some limitations.

The Pharox Blu line comes in 200-lumen and 350-lumen versions, both of which give off less light a 40-watt incandescent bulb’s 450 lumens. That means that the bulbs, which consume less than 5 watts and 8 watts, respectively, won’t give off enough light for many uses, such as lighting a whole room.

The Blu line also has a one-year warranty, versus a three-year warranty for existing Pharox line. They don’t work with a dimmer, a move to save money on manufacturing.

Lemnis is deliberately taking a no-frills approach to get consumers familiar with LED lighting, said Lemnis Lighting co-founder Warner Philips. “Customers want higher-lumen products, but they also want a model that gets them in the game and starts them testing LEDs,” he said.

In the past two years, large lighting companies have introduced LED bulbs able to give off as much light as a 60-watt or 75-watt incandescent priced around $35 or $40. They use about 80 percent less power than incandescent bulbs and are designed to last 15 to 25 years, depending on usage.

Based on online reviews, consumers who have bought LED bulbs are generally happy with the performance of the products. And costs have fallen significantly over the past several months, aided in some places by state or utility rebates.

But most consumers are not willing to do the math on how quickly LEDs pay for themselves in energy savings, Philips said. That’s causing concern in the lighting industry over how strong consumer demand is for general-lighting LEDs.

Even though they give off relatively little light, Philips suggested that the new Blu bulbs can be used for downward directional lighting in offices or in recessed cans in a kitchen. Both will be sold only through the company’s Web site, with sales yielding a low-margin profit, Philips said.

Lemnis is working on brighter LED bulbs too. In the second quarter, it plans to introduce three higher-priced models with a lighting range between 400 lumens and 800 lumens, or roughly from that of a 40-watt to a 60-watt incandescent. Prices for those will start around $10, be dimmable, and have a longer, three-year warranty, Philips said.

By:  Martin LaMonica
Source: http://news.cnet.com/8301-11386_3-57377473-76/lemnis-unwraps-led-bulb-under-$5/?tag=mncol;cnetRiver

Gallium Helping Us Stay Connected

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Rare Earth Metal - Gallium

The element so instrumental in the success of CIGS or Copper Indium Gallium Selenide solar panels garners little respect. If you do some research on Gallium you will see very few articles on this element. What you see is people talking about how to make melting spoons, and talk of the metal melting in your hand due to its low melting point of 85° F or 29.8° C. Here we are going to go over the history of Gallium and its uses in technology today.

Gallium has the symbol of Ga and the atomic number 31 on the periodic table of the elements. In 1875 Paul Emile Lecoq de Boisbaudran discovered Gallium spectroscopically. He saw Gallium´s characteristic two violet lines. Gallium does not occur free in nature. Lecoq was able to obtain the free element using electrolysis.

Gallium is found in bauxite, sphalerite and coal. It is primarily extracted from Aluminum and Zinc production. The exact amounts mined and recycled are very difficult to quantify. According to the United States Geological Survey the total amount mined in 2010 was approximately 106 t and the total recycled was approximately 78 t. Gallium supply is highly reliant on other Aluminum and Zinc mining for its supply, when the prices of the base metals fall the amount of Gallium available will be highly affected. Similar to other rare industrial metals, mining companies will not invest in the production of these metals because the markets are so small.

The uses of Gallium are found all around you. Semiconductors, LED´s, medicine, electronic components, CIGS solar and new tech like IGZO (Indium, Gallium, Zinc and Oxygen) LCD screens. The new iPhone 5 will have this kind of LCD. Over 90% is used in electronic components in the form GaAs (Gallium Arsenide). Recently CIGS solar panels reached an unprecedented 20.3% efficiency once again proving that CIGS is the most efficient form of solar on the market. The technology that will greatly increase the use of Gallium is smartphones. Analysts predict that smartphone use will grow at a rate of 15-25% over the next several years. Recently LED´s backlit screen TV´s and computer monitors have been all the rage. The LED screen market will continue to grow, further putting strain on the small Gallium supply.

The top producers of Gallium are China, Kazakhstan and Germany. Once again China has a strong position in the production of a rare industrial metal. The difference with Gallium is that almost 40% of the metal produced every year is coming from recycling.

With all of the new technologies coming along using Gallium what will the market for this metal look like in a few years? Unlike some metals like Silver and Gold, Gallium is not traded on the LME (London Metal Exchange). This makes the price of Gallium very stable. Rare industrial or technical metals are small markets with big possibilities. So if you are looking for an investment that is rarely talked about, Gallium could be a good option.

 By: Randy Hilarski - The Rare Metals Guy

LED Applications Growing, Will Only Lead to More REE Demand

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LEDs

An end product’s supply chain can be far reaching, with parts or all of the upstream and downstream producers sometimes getting hit at different times by economic forces.

This appears to be happening in China’s domestic LED market, which has seen a marked fall-off in demand, according to the China Strategic Monitor. That’s hit pricing during the second half of this year.

“Investment plans are being curtailed both in the upstream and downstream compared to those presented last year,” according to the report. “Despite this there are many companies still attracted to the market and many pharmaceutical companies and even wineries in South China are moving into LED lighting products. Based on this trend the industry is likely to realize large-scale production capacity over the next 2 or 3 years and pricing for products should fall a further 20-30%.”

Industry watchers reckon 10% of LED-driven businesses in China could go bankrupt this year. And one chief executive, speaking at the recent China Industrial Development Forum for the Low Carbon Economy, said 90% of all China’s LED businesses are running at a loss.

Interesting. The country’s Guangdong province said earlier this month that it had exported US$3.81 billion worth of lighting products between January and August – that’s a 21% increase over the same time period last year.

“Customs authorities indicated that the main export market is still Europe and America with the two taking up 63.2% of the total,” a report said. “Though exports to Hong Kong, Japan and other ASEAN countries are up 60% on last year.”

The massive rise in LED exports is ascribed to the increasing trend of upgrading to energy-efficient lighting combined with the higher production values and quality in China, according to the report.

Still, various companies producing LED products complain that the industry is hit with high selling, raw material and R&D costs. So, while a company reports a 32% jump in LED sales in the third quarter of 2011when compared to 2Q10, the senior executives also talk about the need to implement structural changes, improve execution, reduce overhead costs and initiate job cuts.

Now, the LED industry uses a wide range of phosphor materials to convert light emission from LED chips into a different wavelength. So, combining a blue LED with one or more phosphors can create a white LED. Many of the phosphors used in LEDs contain rare-earth elements, the most common one being the yttrium aluminum garnet, which is doped with cerium.  Another phosphor, called TAG, contains terbium, while silicate and nitride phosphors are commonly doped with cerium or europium.

 Here’s a small example of how LED products are being used: Kingsun Optoelectronic Co has just installed more than 10,000 street lights containing one million high-efficiency white LEDs along 75 miles of roads in Shenzhen. Kingsun anticipates a 60-percent reduction in energy consumption compared to the high-pressure sodium fixtures that have been replaced in the upgrade.

And while LEDs are now widely recognized as emerging light sources for general illumination, it turns out that LED lighting can also be used in a broad range of life-science applications such as skin-related therapies, blood irradiation, pain management, hypertension reduction and photodynamic therapy, which, when combined with drugs, is finding its way into cancer research.

In other words, the LED industry is only now just starting to be exploited, meaning demand will grow across all sectors. Translation – more rare earths will be needed in producing these products as research advances are made and commercial producers become more lean and efficient.

Source: http://www.raremetalblog.com/
By: Brian Truscott

Forget oil, Indium may be the next most precious resource

by Thomas J Thompson on October 30, 2010

Indium Ingots

I will grant you that Indium finger isn’€™t a good title for a Bond movie, but Indium may certainly be worth hoarding.

Let’s start with the basics. Indium is a chemical element with chemical symbol In and atomic number 49. It is rare, very soft, malleable and is easily fusible. It is a post-transitional metal that is chemically similar to aluminum or gallium. Zinc ores are the primary source of indium and is named for the indigo blue line in its spectrum that was the first indication of its existence in ores, as a new and unknown element.

Here€™s why it’€™s important€“ today’€™s mobile touchscreen gadgets, along with all liquid crystal displays, rely on it, and it could be gone within the decade.

Indium is the principal component in indium tin oxide (ITO). ITO has unique qualities that make it unique. It is a rare example of a material that is both electrically conducting and optically transparent, which means it does not absorb photons of light. Absorption occurs when a photon’€™s energy matches that needed to knock an electron into an excited state. In a metallic conductor, where there is a free-flowing “€œsea”€ of electrons with many different energy states, his almost always happens. Accordingly, almost all metals are highly absorbing and entirely opaque. Not so ITO. It is transparent like glass, but also conducts.

ITO changed the way touchscreen works. The common methods, prior to ITO, were to use infrared LEDs ranged around the screen to fire beams that are blocked by a touch, but those were bulky and required a lot of power to run; or to use a stylus and two layers of ITO separated by a slight gap. Tapping this resistive screen with the stylus brought the two layers together, allowing a current to pass. New touchscreen devices utilize the fact that your finger is conductive to do away with the stylus. Touching the screen changes its capacitance at that location, a change picked up by a single layer of ITO.

The problem is that no one is sure how much indium there is left. The US Geological Survey estimates that known reserves of indium worldwide amount to 16,000 tons (63% in China). At the current rate of consumption, those reserves will be exhausted by 2020. Those numbers don’t take into account recycling or any new sources of indium. According to Indium Corporation, the largest processor of indium, claims that, on the basis of increasing recovery yields during extraction, recovery from a wider range of base metals (including tin, copper and other polymetallic deposits) and new mining investments, the long-term supply of indium is sustainable, reliable and sufficient to meet increasing future demands.

According to James Mitchell Crow writing in New Scientist magazine, the increasing demands for ITO promise to make ITO rare and, therefore, more expensive. The touchscreen market is currently projected at $1.47 billion and will balloon to $2.5 billion by 2017. This means that the race to find a replacement for ITO are on! Some of the replacements under consideration are zinc oxide, but it’€™s not as conductive, transparent or physically resilient as ITO. Another consideration is to stretch the current reserves of indium by mixing it with cadmium oxide. Doing so may reduce the amount of indium necessary per screen by 80%. Unfortunately, cadmium is highly toxic and prone to cracking. More futuristic thoughts include the development of conducting polymers, but these are often prone to ultraviolet light and oxygen.

So is it the end of the touchscreen era? Probably not €“ thanks to nanotechnology.

One solution may be carbon nanotubes. Carbon is a chemical chameleon. In some guises, it is the most light-absorbing material known. Pare it down to nanoscale structures, however, and it becomes transparent. Carbon nanotubes are essentially graphene sheets rolled up into tiny cylinders. Graphene, the wonder material behind the award of this year’€™s Nobel prize in physics, consists of sheets of graphite just a single atom thick. The problem is that individual nanotubes are highly conductive, but the electrons racing across their surface stop dead when they get to the end of a nanotube and have to jump to the next.

Another idea may be metal nanowires. Experiments with silver nanowires have shown transparency of 85 percent and a conductivity only a fraction behind that of ITO. Unfortunately, silver nanowires are 10 times as expensive to produce as top-grade ITO. Other concepts include a mechanical switch behind every pixel, registering the force as the screen is touched, but using pressure-sensing technology means doing away with the protective glass cover, making it more susceptible to damage. Another possibility is an optical technology that incorporates a light-detecting element into each pixel. These light sensors turn the screen into a scanner that can detect and follow a finger. However, it needs significant processing power to continually analyze the screen surface and works only a quarter as fast as a traditional laptop touchpad.

In any case, such innovations do not address the more fundamental problem that, touch or no touch, the electrodes that supply power to the pixels of LCD displays themselves depend on ITO. That will be solved only by the development of new materials that mimic ITO’€™s intensely desirable combination of transparency and conductivity.

Swiss Metal Assets appears on Deutsche Welle Television Show