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According to a recent report by the Physicist Organization Network, a new manufacturing technology is expected to significantly reduce the production costs of light-emitting diodes (LEDs) and further promote its popularization.
The research conducted by researchers at Siemens' subsidiary Osram Opto Semiconductors succeeded in producing GaN LED chips on silicon substrates, replacing the more expensive sapphire substrates currently used.
Silicon is a standard semiconductor material and has excellent performance as an LED substrate, such as large size, low cost, easy processing, and good electrical conductivity. However, the technical difficulty is that the thermal expansion coefficients of silicon and gallium nitride are different, and stress is easily generated in the manufacturing process, resulting in uneven film thickness or cracking, and thus has not been widely used in the LED industry. Through a special process, the new technology not only avoids the cracking that occurred before, but also makes the new LED's stability and brightness comparable to traditional sapphire-based LEDs, and is very suitable for high-power solid-state lighting.
LED is an energy-efficient lighting solution that is considered the most promising alternative to traditional light sources. However, the production cost of LED has been higher than other more mature lighting products so far, so it has not been widely used in daily life. Through the use of new technologies, LED production is expected to use a larger area of ​​silicon, which will be a major increase in LED production efficiency.
With this technology, OSRAM has successfully produced a high-performance 150-mm (6-inch) LED wafer. Researchers have begun to adjust the production process to produce 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 a 50-mm (2-inch) or 100-mm (4-inch) sapphire substrate. If silicon-based GaN technology is used, at least 75% of raw material costs can be saved.
At present, this kind of film-based new LED is still in the prototype stage of the sample, and will be tested for reliability in a real-life environment. Preliminary experiments have shown that blue and white silicon-based LEDs made with this technology can achieve similar performance as sapphire substrates currently on the market. It is expected that the first commercial LED product using this technology will be available two years later. (Wang Xiaolong)
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