The Main Challenge of LED Industry

In last article, we talk about that there’s a consensus that most of those barriers. They should be removed in the next 2-3 years. Impressive energy efficiency progress are announced on a regular basis by LED manufacturers and reliability is improving as engineers become aware of the challenges posed by the design of a flawlessly integrated LED luminaire (GE recently identified more than 100 possible failure mode in LED light engines).

Multiple standardization organization are working on defining and implementing testing and performance standards and communicating them to the public. Solid state lighting is progressing niche by niche.  More municipalities are testing LED streetlight and some have already committed to massive retrofits (200,000 street lights in Los Angeles). Adoption in commercial and retails lighting, while still low in volume is progressing fast (announcements from Wall Mart, Starbucks…). While we all have our eyes focused on residential applications, it’s important to realize that homes are the smallest segments (in term of lumens) compared to industrial, commercial and municipal lighting. However, for most, it remains the ultimate frontier.

But even this application now seems within reach and LED replacement bulbs might come to your home faster that you expected. Don’t rush yet though, as low quality products are still flooding the market and might create a negative initial perception of the technology, a risk that the industry is aware off and trying to control by working on performance standard (make sure you get products meeting or exceeding the Energy star criteria for solid state lighting). In Japan, the largest electronic manufacturers are making a strong push with quality products. Toshiba Lighting and Technology introduced a 60W equivalent replacement LED bulb for JPY9,000 in late 2008. The same product now goes for less than JPY4,000. Sharp launched similar offers and the price is now expected to reach  JPY2,000 in 2010. At this pace, most now expect the cost of LED replacement bulbs to reach the $10 for 1000 lumen target commonly accepted as the “magic” number that will trigger massive adoption by 2012.

In the US, Philips released the first LED bulb to participate to LPrize contest organized by the US Department Of Energy to reward the first 60W replacement LED bulb to meet aggressive performance targets.  A lot of credible light bulb replacements could be seen at the recent Strategies In Light conference exhibition floor and CREE is planning to release a retail version of its award winning LR6. The price point at which it will be released will send a strong signal to the industry.

Fantastic Motion Sensing LED Light

There are times when it’d make life a lot easier if lights would just come on.  Be it because you usually have your hands full in that area or any other reason, it’d just be nice.  Now this little motion sensor won’t turn on all the lights in the room, but it will turn on a small light to help you find your way.  Plus it could be used as a security device, so you’ll know if someone is moving around where they shouldn’t.

This simple little light could even be used in other areas besides in your home.  It could also be grabbed for when you go camping if you need some small lights to keep you from tripping over anything.  On the light itself you can adjust the sensitivity of the motion sensor.  You can also just shut off the light entirely.  It runs on 4 AAA batteries which aren’t actually included.

LED Makers Promise to Shake up Global Market

LEDs, once confined to the tiny red indicator lights on TV remote controls, have now grown to illuminate TV screens themselves and promise to shake up the global lighting market.

LED (light emitting diode) backlit TVs were heavily featured at the Consumer Electronics Show in Las Vegas this month, as manufacturers announced products intended to emulate the success seen by Samsung in 2009.

Samsung, which has 80 per cent of the US market for LED TVs, aims to quadruple global sales in 2010 to more than 10m.

But manufacturers such as LG, another Korean player, say Samsung will not have things all its own way as LED-backlit TVs become available at entry-level as well as premium prices. LG will offer cheaper edge-lit LED technology, which requires fewer arrays of diodes, on its entry-level TVs and full LED backlights on premium models.

LEDs have graduated from use in mobile phone screens to backlights for notebooks, PCs and now TVs and monitors.

They offer better brightness and contrast, energy savings and slimmer screens than those using the established cold cathode fluorescent lamps (CCFLs) now used for backlighting.

LED technology was first introduced in 1962, beginning with a low-intensity red light. Semiconductor-based diodes or valves produce light from the excitation of electrons as they are moved over a “light” bridge by a direct electrical current. LEDs differ from traditional incandescent light bulbs, which produce their light from heat generation.

Over the years, white LEDs have been developed by combining chips that produce different colours into a single package, or by adding a yellow phosphor layer. Improvements in light intensity and cost reductions are now resulting in wider adoption of LEDs.

Pete Moran of the DCM venture capital firm says LEDs have advantages such as longer life and greater efficiency compared with both incandescents and the energy-saving compact fluorescents with which consumers are currently replacing them.

As well as the green argument, there are manpower savings from LED’s longevity. Cities such as San Francisco, San Jose, New York and Minneapolis are testing LED street lamps that will not need regular bulb replacement by lighting crews. In retail, Walmart and Starbucks are replacing lighting in their US stores with LED bulbs to cut energy consumption.

But as big semiconductor makers such as Samsung and Micron begin to take an interest in the LED industry, it could eventually take on the same characteristics as the DRAM, or flash memory, industries, according to analyst Daniel Amir.

The LED industry will then become cyclical, with a period of oversupply as early as the second half of 2011, according to Lazard, although demand should still be growing at rates of 20 to 30 per cent a year.

Copyright The Financial Times Limited 2010. You may share using our article tools. Please don’t cut articles from FT.com and redistribute by email or post to the web.

Rockler Recalled LED light kits

Legal news for product liability attorneys. A voluntary recall of LED light kits was announced after discovery of defective wiring.

CPSC alerts product liability lawyers- Rockler Companies Inc. announced voluntary recall of LED light kits.

Washington, D.C.—Rockler Companies, Inc., of Medina, Minnesota and the U.S. Consumer Product Safety Commission (CPSC) have announced a voluntary recalled of LED light kits. Nearly 2,200 LED light kits were recalled on January 12, 2010, as reported by the CPSC.

The CPSC has urged consumers to stop using the recalled LED light kits immediately unless otherwise instructed after the discovery of defective wiring in the light kits. The defective wiring can cause the battery pack to overheat and explode, which poses a risk of burn and fire. At this time no injuries and/or instances have been reported. This recalled product is described as Rockler LED lights with either an interchangeable spotlight head, or a magnifying head. The recalled product models have stock numbers 26429 (spotlight or 27017 (magnifying). The stock numbers are printed on the products packaging. The LED light kits were sold at Rockler Woodworking and Hardware and other specialty stores across the country from March 2009 through October 2009 for the retail price of $60. All consumers who have purchased the product can contact Rockler Companies at (800) 260-9663 to receive a fee repair kit and installation instructions.

Nanosys Do Efforts to Improve LEDs

As we all know that in this struggling economy, businesses as well as the general populace are all struggling to do more with less. In the case of LED and nanotechnology, however, that may not be necessarily a bad thing.

Take for example the work showcased at CES by Nanosys, a company that has developed a method to add nanomaterials to blue LEDs that improves the appearance of LED lighting. Their efforts have created an LED light that combines the energy efficiency of a blue LED; with a nanotechnology layer that alters its blue appearance into a warm white light that is better than standard LED lighting.

The benefits of the added nanotech material not only means improving the quality of the emitted light for backlit LED displays
, but doing so while still maintaining a low power profile. Plus Nanosys claims, the process can be added to a company’s assembly line for electronic products without the need for major retooling.

So expect to see better looking LED lighting in the near future as Nanosys nanotechnology starts to appear in televisions and other lighting products beginning later this year.

The Advantages of LED Lights

As we all know that the future of energy efficient lighting is LED. Not only are LED’s environmentally friendly, the light represents a true white light. A recent press release printed in the Village News on ways to cut energy expenditures missed the mark completely.

Although it is true that CFL bulbs do save energy, they also contain mercury, which is a hazardous material, and these bulbs cannot be disposed of easily. If the bulb is broken, there is a huge problem because the mercury is disbursed throughout the area.

The future in lighting is the use of LED (light emitting diodes) lamps.

First, the operational life of current white LED lamps approaches 100,000 hours. The key strength of LED lighting is reduced power consumption approaching 80 percent efficiency, compared to an incandescent lamp, which operates at about 20 percent efficiency. LED lamps are now available on the Internet and at Wal-Mart.

If, in fact, a bulb burns out in your lifetime, it can be disposed of easily and if broken there is no contamination.

I would urge all Village News readers to learn about LEDs and stop purchasing the dangerous CFL mercury contained lamps.

The folks responsible for traffic lights have started replacing the red, yellow and green lamps with LEDs; you can distinguish the LED lamp because the light is made up of clusters of round LEDs which make up the light.

I recently purchased a GE PAR 30 long neck LED lamp at Wal-Mart to try in my kitchen ceiling. I am very pleased and it only draws 10 watts of power, compared to the 65 watt incandescent bulb that the LED replaced.

Comparing Xenon Lights and LED Light

An updated study has been published by Limited, developer of thin-form supercapacitors that compare flash solutions for camera phones — xenon, standard LEDs powered by a battery, and high-current LEDs powered by a supercapacitor using the company’s BriteFlash(TM) power architecture. The study tested each solution’s ability to deliver the light energy needed to take digital-still-camera-quality pictures in low-light conditions, and also compared shutter requirements, ease of design-in, safety and size.

The original report from October 2006 compared light power and energy using 1.3 to 3.2-megapixel camera phones. The new report includes data from 5-megapixel camera phones released in the last year, and also considers advancements in camera sensors, xenon flash units, high-power white LEDs (WLEDS) and LED flash drivers.

Tests again showed that the LED BriteFlash approach delivers more light energy than most xenon flashes in a thin form factor suitable for slim camera phones and digital cameras.

Clear pictures in dim environments require sufficient light energy — the total amount of light received by each pixel in the camera sensor — during image-capture time. “People often wrongly assume that light power, which is the brightness or intensity of the flash, is the key because it’s what draws our attention, but it’s really the light energy that counts,” said Pierre Mars, CAP-XX vice president of applications engineering.

To calculate light energy, one would multiply light power (in lux) by the duration of the flash exposure (in seconds): Light power (lux) x flash exposure time (sec) = light energy (lux.sec). Ten to fifteen lux.sec of light energy is ideal for high-resolution pictures:

–  Xenon flash tubes driven by electrolytic storage capacitors deliver
higher light power, but over a very short flash exposure.
–  High-current LEDs driven by a supercapacitor deliver lower light
power, but over a longer flash exposure to generate more light energy.

Flash solutions tested:

–  Xenon: SonyEricsson K800, LG KU990, Nokia N82 and Samsung G800, all
with 5-megapixel cameras but with varying size electrolytic storage
capacitors.
–  Standard battery-powered LEDs: Nokia N73 (3.2-megapixel) and N96 (5-
megapixel)
–  Supercapacitor-powered LEDs: To demonstrate the BriteFlash approach,
CAP-XX used a small, thin (20mm x 18mm x 3.8mm thick), dual-cell
supercapacitor to drive a two-LED array of Philips LUXEON® PWM4s at 2A
each or 4A total during the flash pulse.

Fascinating New Generation OLEDs

With their minuscule energy consumption and 20-year life expectancy, LED light bulbs have grabbed the consumer’s imagination.

But an even newer technology is intriguing the world’s lighting designers: OLEDs, or organic light-emitting diodes, create long-lasting, highly efficient illumination in a wide range of colors, just like their inorganic LED cousins. But unlike LEDs, which provide points of light like standard incandescent bulbs, OLEDs create uniform, diffuse light across ultrathin sheets of material that eventually can even be made to be flexible.

Ingo Maurer, who has designed chandeliers of shattered plates and light bulbs with bird wings, is using 10 OLED panels in a table lamp in the shape of a tree. The first of its kind, it sells for about $10,000.

He is thinking of other uses. “If you make a wall divider with OLED panels, it can be extremely decorative. I would combine it with point light sources,” he said.

Other designers have thought about putting them in ceiling tiles or in Venetian blinds, so that after dusk a room looks as if sunshine is still streaming in.

Today, OLEDs are used in a few cellphones, like the Impression from Samsung, and for small, expensive, ultrathin TVs from Sony and soon from LG. (Sony’s only OLED television, with an 11-inch screen, costs $2,500.) OLED displays produce a high-resolution picture with wider viewing angles than LCD screens.

In 2008, seven million of the one billion cellphones sold worldwide used OLED screens, according to Jennifer Colegrove, a DisplaySearch analyst. She predicts that next year, that number will jump more than sevenfold, to 50 million phones.

But OLED lighting may be the most promising market. Within a year, manufacturers expect to sell the first OLED sheets that one day will illuminate large residential and commercial spaces. Eventually they will be as energy efficient and long-lasting as LED bulbs, they say.

Because of the diffuse, even light that OLEDs emit, they will supplement, rather than replace, other energy-efficient technologies, like LED, compact fluorescent and advanced incandescent bulbs that create light from a single small point.

Its use may be limited at first, designers say, and not just because of its high price. “OLED lighting is even and monotonous,” said Mr. Maurer, a lighting designer with studios in Munich and New York. “It has no drama; it misses the spiritual side.”

“OLED lighting is almost unreal,” said Hannes Koch, a founder of rAndom International in London, a product design firm. “It will change the quality of light in public and private spaces.”

Mr. Koch’s firm was recently commissioned by Philips to create a prototype wall of OLED light, whose sections light up in response to movement.

Because OLED panels could be flexible, lighting companies are imagining sheets of lighting material wrapped around columns. (General Electric created an OLED-wrapped Christmas tree as an experiment.) OLED can also be incorporated into glass windows; nearly transparent when the light is off, the glass would become opaque when illuminated.

Because OLED panels are just 0.07 of an inch thick and give off virtually no heat when lighted, one day architects will no longer need to leave space in ceilings for deep lighting fixtures, just as homeowners do not need a deep armoire for their television now that flat-panel TVs are common.

The new technology is being developed by major lighting companies like G.E., Konica Minolta, Osram Sylvania, Philips and Universal Display.

“We’re putting significant financial resources into OLED development,” said Dieter Bertram, general manager for Philips’s OLED lighting group. Philips recently stepped up its investment in this area with the world’s first production line for OLED lighting, in Aachen, Germany.

Universal Display, a company started 15 years ago that develops and licenses OLED technologies, has received about $10 million in government grants over the last five years for OLED development, said Joel Chaddock, a technical project manager for solid state lighting in the Energy Department.

Armstrong World Industries and the Energy Department collaborated with Universal Display to develop thin ceiling tiles that are cool to the touch while producing pleasing white light that can be dimmed like standard incandescent bulbs. With a recently awarded $1.65 million government contract, Universal is now creating sheetlike undercabinet lights.

“The government’s role is to keep the focus on energy efficiency,” Mr. Chaddock said. “Without government input, people would settle for the neater aspects of the technology.”

G.E. is developing a roll-to-roll manufacturing process, similar to the way photo film and food packaging are created; it expects to offer OLED lighting sheets as early as the end of next year.

“We think that a flexible product is the way to go,” said Anil Duggal, head of G.E.’s 30-person OLED development team. OLED is one of G.E.’s top research priorities; the company is spending more than half its research and development budget for lighting on OLED.

Exploiting the flexible nature of OLED technology, Universal Display has developed prototype displays for the United States military, including a pen with a built-in screen that can roll in and out of the barrel.

The company has also supplied the Air Force with a flexible, wearable tablet that includes GPS technology and video conferencing capabilities.

As production increases and the price inevitably drops, OLED will eventually find wider use, its proponents believe, in cars, homes and businesses.

“I want to get the price down to $6 for an OLED device that gives off the same amount of light as a standard 60-watt bulb,” said Mr. Duggal of G.E. “Then, we’ll be competitive.”

LED Lights Show Great Promise

As we all know that LED technology shows great promise in lighting the way for Tech to a more economic and environmentally-friendly direction.

Facilities faculty has completed several lighting renovations already on campus, including converting all the lighting in the Tennenbaum Auditorium to LED lamps. This project alone reduced electricity consumption by 39.2%, and light per square foot more than doubled. They also installed LED can lights on the second floor of the Price Gilbert Library.

“We are currently working on several projects in the IBB building to convert high ceiling fixtures to LED and will eventually expand this to other buildings. The architecture building is next on the list,” said Sanford Fong, Facilities department Electrical Engineer I.

Heat, output and energy usage are the greatest factors in LEDs’ benefits. Since the lights do not rely on a filament, they don’t burn out as quickly and less of the energy emitted is heat (very beneficial for stage work, which is often under extremely hot rows of lights). Since less energy is emitted as heat, it does not require as much energy to produce the light, saving money.

Thanks to a recent cost drop in semiconductor material, they are now a viable option for widespread use. This has opened a window for mass-emplacement of LEDs, like in department stores.

Walmart is pursuing improvements to energy and cost savings by installing LED lighting in their refrigerated cases. The new fixtures and dimming capabilities could net 66% in energy savings. If 500 Wal-mart stores were to use these, it would reduce carbon dioxide emissions by 35 million pounds and save the company $2.6 million per year. The lights could add over three years to the refrigerated cases’ lighting lifetime.

LED lighting can also be applied to large parking lot lights, medium hallway and stairwell lights and small classroom lights. They can last over 50,000 hours (over five years) and the lower power consumption with equal or greater luminosity than conventional lighting could save big money for Tech.

“LEDs save a great deal over incandescent lamps. For example, the can light we are installing in the Petit building is a 12-Watt fixture comparable to an 80-Watt incandescent in lighting output,” Fong said. Such a fixture could save 85% in energy.

Facilities will soon procure a street light test unit to evaluate more demanding applications on campus like streetlights, emergency lights and shop lights. Thanks to the higher power output and longevity, any light fixture that is on a great deal of time or is too hard to reach is a good candidate for an LED application.

Indoor lighting sees a change for the better as well. The pervasive use of fluorescent lighting in classrooms has garnered criticism for eye strain and headaches from the (though too fast to notice) lights’ high-frequency flickering; however, LED lighting is flicker-free. Fluorescent lamps are also less efficient, less longevous, and less environmentally friendly (they contain mercury). In this sense, changing the lights may actually directly improve student and faculty health and performance.

Tech has been a leading institution in LED technology. In 2002, ECE professor Russell Dupuis earned the highest national honor in science, the National Medal of Technology, for his work in developing and commercializing LEDs in applications like traffic lights and automotive lighting.

Ultrathin Inorganic LEDs

There is now a new process under development to create ultrathin, ultrasmall inorganic light-emitting diodes (LEDs) and assembling them into large arrays, which offers new classes of lighting and display systems with interesting properties.

Applications for the arrays, which you can print onto flat or flexible substrates ranging from glass to plastic and rubber, include general illumination, high-resolution home theater displays, wearable health monitors, and biomedical imaging devices.

“Our goal is to marry some of the advantages of inorganic LED technology with the scalability, ease of processing, and resolution of organic LEDs,” said John Rogers, the Flory-Founder chair professor of Materials Science and Engineering at the University of Illinois.

Compared to organic LEDs, inorganic LEDs are brighter, more robust, and longer-lived. Organic LEDs, however, are attractive because you can form them on flexible substrates, in dense, interconnected arrays. The researchers’ new technology combines features of both.

“By printing large arrays of ultrathin, ultrasmall inorganic LEDs and interconnecting them using thin-film processing, we can create general lighting and high-resolution display systems that otherwise could not be built with the conventional ways that inorganic LEDs are made, manipulated, and assembled,” Rogers said.

To overcome requirements on device size and thickness associated with conventional wafer dicing, packaging, and wire bonding methods, researchers developed epitaxial growth techniques for creating LEDs with sizes up to 100 times smaller than usual. They also developed printing processes for assembling these devices into arrays on stiff, flexible, and stretchable substrates.

As part of the growth process, a sacrificial layer of material embeds beneath the LEDs. When fabrication is complete, a wet chemical etchent removes this layer, leaving the LEDs undercut from the wafer but still tethered at anchor points.

To create an array, a rubber stamp contacts the wafer surface at selected points, lifts off the LEDs at those points, and transfers them to the desired substrate.

“The stamping process provides a much faster alternative to the standard robotic ‘pick and place’ process that manipulates inorganic LEDs one at a time,” Rogers said. “The new approach can lift large numbers of small, thin LEDs from the wafer in one step, and then print them onto a substrate in another step.”

By shifting position and repeating the stamping process, LEDs can transfer to other locations on the same substrate. In this fashion, you can create large light panels and displays from small LEDs made in dense arrays on a single, comparatively small wafer. And, because the LEDs can be placed far apart and still provide sufficient light output, the panels and displays can be nearly transparent. The thin device geometries allow the use of thin-film processing methods, rather than wire bonding, for interconnects.

In addition to solid-state lighting, instrument panels, and display systems, the new method also allows for flexible and even stretchable sheets of printed LEDs, with potential use in the health-care industry.

“Wrapping a stretchable sheet of tiny LEDs around the human body offers interesting opportunities in biomedicine and biotechnology,” Rogers said, “including applications in health monitoring, diagnostics, and imaging.”