2014 DOE Solid-State Lighting Manufacturing R&D Roadmap

Manufacturing Roadmap Solid-State Lighting Research and Development Prepared for the U.S. Department of Energy August 2014 Prepared by Bardsley Consulting, Navigant Consulting, SB Consulting, and SSLS, Inc. DISCLAIMER This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government, nor any agency thereof, nor any of their employees, nor any of their contractors, subcontractors, or their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency, contractor, or subcontractor thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. Authors Norman Bardsley Bardsley Consulting Stephen Bland SB Consulting Dan Chwastyk Navigant Consulting, Inc. Lisa Pattison SSLS, Inc. Morgan Pattison SSLS, Inc. Kelsey Stober Navigant Consulting, Inc. Mary Yamada Navigant Consulting, Inc. SSL Manufacturing Roadmap SOLID STATE LIGHTING RESEARCH AND DEVELOP MENT TABLE OF CONTENTS 1 OVERVIEW OF SSL MANUFACTURING STATUS .......................................... 7 1.1 SSL Manufacturing Supply Chain .......................................................................... 8 1.1.1 LED-Based SSL Manufacturing ........................................................................ 9 1.1.2 OLED-Based SSL Manufacturing ................................................................... 10 1.2 Global and U.S. Production .................................................................................. 11 1.2.1 LED .................................................................................................................. 12 1.2.2 OLED ............................................................................................................... 17 1.3 The U.S. Department of Energy (DOE) SSL Program ......................................... 20 1.3.1 Program Elements ............................................................................................ 20 1.3.2 Cost Drivers ..................................................................................................... 21 2 LED PACKAGE AND LUMINAIRE ROADMAP .............................................. 31 2.1 LED Manufacturing Equipment ........................................................................... 31 2.1.1 Epitaxial Growth Equipment............................................................................ 31 2.1.2 Wafer Processing Equipment ........................................................................... 34 2.1.3 LED Packaging Equipment .............................................................................. 35 2.1.4 Luminaire and Module Assembly Equipment ................................................. 36 2.1.5 Test and Inspection Equipment ........................................................................ 37 2.2 LED Manufacturing Materials .............................................................................. 39 2.2.1 Substrate Materials ........................................................................................... 39 2.2.2 Chemical Reagents ........................................................................................... 43 2.2.3 Packaging Materials ......................................................................................... 43 2.2.4 Down-Converter Materials .............................................................................. 45 2.2.5 Encapsulation and Matrix Materials ................................................................ 46 2.3 LED Die Manufacturing ....................................................................................... 47 2.3.1 Epitaxial Growth .............................................................................................. 47 2.3.2 Wafer Processing ............................................................................................. 48 2.3.3 Die Singulation ................................................................................................ 51 2.4 LED Package Manufacturing ................................................................................ 51 2.4.1 Die Packaging .................................................................................................. 52 2.4.2 Down-Converter Application ........................................................................... 54 2.4.3 Encapsulation and Lensing .............................................................................. 56 2.5 LED Luminaire Manufacturing ............................................................................ 56 2.5.1 LED Die and Packages in Luminaires ............................................................. 56 2.5.2 Remote Phosphors ............................................................................................ 58 2.5.3 Optical Component Manufacturing.................................................................. 58 2.5.4 LED Driver Manufacturing .............................................................................. 59 2.5.5 Lamp and Luminaire Manufacturing ............................................................... 60 2.5.6 Test and Inspection .......................................................................................... 63 2.6 LED Modeling and Simulation ............................................................................. 63 2.6.1 Cost Modeling .................................................................................................. 63 2.6.2 Design for Manufacturing ................................................................................ 64 2.6.3 Manufacturing Process Simulation .................................................................. 65 2.6.4 Luminaire Reliability Modeling ....................................................................... 65 2.7 LED Manufacturing Priority Tasks for 2014 ........................................................ 67 3 OLED PANEL AND LUMINAIRE ROADMAP ................................................. 69 3.1 OLED Design Considerations ............................................................................... 69 3.2 OLED Manufacturing Materials ........................................................................... 71 3.2.1 Organic Stack Materials ................................................................................... 71 3.2.2 Substrates ......................................................................................................... 74 3.2.3 Electrodes and Current Spreading Layers ........................................................ 76 3.2.4 Light Extraction Layers.................................................................................... 77 3.2.5 Integrated Substrates ........................................................................................ 79 3.2.6 Encapsulation ................................................................................................... 80 3.3 OLED Manufacturing Equipment......................................................................... 81 3.3.1 Vacuum Processing Equipment ....................................................................... 82 3.3.2 Solution Processing Equipment ....................................................................... 83 3.3.3 Roll-to-Roll Processing Equipment ................................................................. 85 3.3.4 Encapsulation Equipment ................................................................................ 86 3.4 OLED Panel Manufacturing ................................................................................. 87 3.4.1 Process Integration ........................................................................................... 89 3.4.2 Process Control ................................................................................................ 89 3.4.3 Material Utilization .......................................................................................... 90 3.4.4 Manufacturing Yield ........................................................................................ 91 3.4.5 Manufacturing Cost Model .............................................................................. 91 3.4.6 OLED Luminaire Manufacturing ..................................................................... 94 3.5 OLED Manufacturing Priority Tasks for 2014 ..................................................... 96 4 STANDARDS ........................................................................................................... 99 4.1 SSL Product Definitions ..................................................................................... 100 4.2 Minimum Performance Specifications ............................................................... 100 4.3 Characterization and Test Methods .................................................................... 101 4.3.1 Reliability Characterization and Lifetime Definitions ................................... 103 4.4 Standardized Reporting Formats........................................................................

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