LED Manufacturing

Part 2 of the project (this report) uses the conclusions from Part 1 as a point of departure to focus on two objectives: producing a more detailed and conservative assessment of the manufacturing process and providing a comparative LCA with other lighting products based on the improved manufacturing analysis and taking into consideration a wider range of environmental impacts. In this study, we first analyzed the manufacturing process for a white-light LED (based on a sapphire-substrate, blue-light, gallium-nitride LED pumping a yellow phosphor), to understand the impacts of the manufacturing process. We then conducted a comparative LCA, looking at the impacts associated with the Philips Master LEDbulb and comparing those to a CFL and an incandescent lamp. The comparison took into account the Philips Master LEDbulb as it is now in 2012 and then projected forward what it might be in 2017, accounting for some of the anticipated improvements in LED manufacturing, performance and driver electronics.

We demonstrated the growth of blue LED structures grown on 4-inch and 8-inch Si (111) substrates. GaN layers that have low threading dislocation density (TDD) of 1.6×108/cm2, which is comparable to state of the art in GaN on sapphire, can be obtained on 4-inch Si substrate by using a new TDD reduction technology using a silicon nitride (SiN) interlayer. A dependence of LED device performance on threading dislocation density was studied by using 4-inch Si substrate. A LED manufacturing technology has been developed by using 8-inch Si towards mass production technology. The light output power representing a median performance exceeded 641 mW at 350 mA, which was comparable to state-of-the-art LED.

The present invention is an LED prepared as process for the continuous removal method and apparatus of the exhaust gas, more particularly to a LED according to discharge the process gas is toxic, flammable gas which is used in the manufacturing process, one step wet scrubber and two-phase catalytic reaction was passed through a scrubber to remove relates to a continuous method and apparatus of using the wet scrubber with the catalyst column for preventing environmental pollution and safety LED manufacturing process, the discharge gas by the discharge gas.

The bulk of LEDs sold today are still fabricated using older epitaxial techniques such as LPE and VPE, but have relatively low brightness and a limited color range. The newer high brightness LEDs are fabricated from the InGaAlP and III-Nitride systems, with MOCVD being the preferred growth technique for manufacturing. While these new materials represent a significant increase in performance, they are also more expensive to grow. In this paper we consider the reasons for this, which include a less mature growth technology, lower production volumes, expensive starting materials, process efficiency, equipment throughput and cost, and safety and environmental concerns. Addressing each of these issues in turn, we examine what has already been accomplished, and what may be improved by further advances in equipment and process. A realistic COO model is of great utility in comparing product cost for different device structures, staffing schemes, reactor sizes, etc. We demonstrate that for a dedicated LED manufacturing facility, the lowest epitaxial cost is achieved by running around the clock with the highest throughput reactor that is fully utilized for the desired production level. When maintenance tasks such as cleaning and test or calibration runs are minimized, then materials costs will dominate the epi cost, which leads to the desirability of achieving both the best reproducibility and increasing the process efficiency. We show how in-situ control techniques are now capable of increasing preproducibility and thereby lowering product costs for manufacturing scale MOCVD reactors.

valuable and quality information exchange to perform their daily operations and long-term action plan. Hence, selecting and embracing the right supply chain or business management software has become essential to organization. Most Malaysian manufacturer in prefer in adopting to an enterprise resources planning (ERP) system. However, implementing ERP system successfully is costly and complex, and often shows high disappointment rates or even abandonment due to need of fit with the business or social culture. The study conducted to explore the ERP system implementation in a manufacturing-based organization from the perspective of supply chain management. The ERP system implementation could have either positive or negative affects towards organization or company in terms of performance and innovation. The empirical data were collected using in-depth interview as an instrument in a LED manufacturing company. The result confirm that data cannot be editing after done click, server down and more procedure and process are the causes of ineffective implementation of ERP system in the company. This study gives insight to all top management and supply chain practitioners in the manufacturing industry company in implementing ERP System. Furthermore, the findings of this study could also be beneficial to all ERP users as they would be able to understand the ERP system implementation in sectors apart from manufacturing industry. Finally, the outcome of this study could be useful to ERP system adopters in different developing countries. This is one of the first studies, which adequately covers the challenges faced on ERP implementation itself in a LED-manufacturing firm.

Supply chain management strategies focused on enhancing information sharing in supply chains are capable of making a huge impact on the overall supply chain with the advanced development of information and communication technology. Hence, Sri Lankan export-led manufacturing industry can be benefited from these strategies to take the advantage of the rapidly growing phase of the market. In doing so, it is vital to understand the requirements that maintain effective information sharing flow within this industry. Therefore, the purpose of this study is to analyze the management perspective of the industry in deriving the factors which affect the effective information sharing in Sri Lankan export-led manufacturing supply chains. This study further shows that proper functioning of information sharing creates a significant impact on the Sri Lankan export-led manufacturing supply chains. Exploratory factor analysis was used to identify six major factors which influence the effective information sharing in the supply chain: (1) barriers to effective information sharing flow, (2) quality of the information sharing platform, (3) security level of the information sharing flow, (4) resource availability for the information sharing operations, (5) top management’s concern, and (6) level of alignment of the information sharing platform with external members of the supply chain. Since a similar study has not been carried out in this area with respect to Sri Lankan context, the key findings of this study can act as guidelines for the Sri Lankan export-led manufacturing industry to select the most suitable strategies in order to enhance the supply chain information flow.

Design Robotics is a program of research that places design and its processes and thinking at the forefront of robotic research to enable design-led manufacturing. This paper presents two cases of built works created by Brisbane based UAP Company (Urban Art Projects). UAP is a global manufacturer of urban artworks and architectural facades. The QUT Design Robotics research group and RMIT are collaborating with UAP on an Innovative Manufacturing Cooperative Research Centre (IMCRC) funded project (2017-2022). These cases are part of the Design Robotics Open Innovation Network that has been established to share the outcomes from projects with industry. This paper addresses the question, How can open innovation be employed as a strategy for architectural innovation within a design-led manufacturing organization? In response to the research question, the cases are examined through the theoretical lens of ‘Open Innovation’, which describes how an organisation can purposively manage inward flows of external knowledge, and outward flows of internal knowledge to increase its ability to innovate in line with its business model (West & Bogers, 2014). The manufacture of the two cases employed an open innovation strategy to explore the potentials of advanced manufacturing technologies in collaboration with external partners. As a methodology, the researchers follow a case study strategy by co-locating within the industry partner to do on-site observations and findings. The cases are unique in that they reveal an account of the internal know-how and decision-making processes required to integrate advanced manufacturing technologies into established workflows as part of the innovation process. These built works demonstrate novel approaches to integrating robotic systems and virtual reality into the ideation, communication, design development, and manufacture required to deliver each project.

In the LED manufacturing process, a thin Au film is deposited on a wafer, and then most of it is removed with small pieces of Au film left for electrodes. For this removal, we apply physical cleaning method, which can remove the metal film without chemicals. In this study, we investigate a removal process of a thin aluminum film deposited on a glass surface by steam-water mixed spray. At the initial stage of this process, tiny spots, whose sizes are the order of droplet diameter, are observed. And then very characteristic removal profiles, which are typically lines with sub-millimeter width, are observed. We discuss the removal mechanism due to high-speed droplet impact.

gradually replace conventional lighting due to their improvement in light efficiency, superior lifetime, color quality, and the absence of mercury. The epitaxial growth of gallium nitride (GaN) layers is one of the most challenging steps in the LED manufacturing process. Process gases of a defined quality and reliability are essential in order to continue improving the LED’s characteristics. Gas purification is hence commonly used to eliminate variations generated by the gas source and the gas distribution system. Improved ammonia (NH3) purification systems have been developed to expand the range of impurities that can be eliminated. This article presents the results obtained with these new NH3 purification systems using the most advanced analytical techniques.

Since LED became an attractive alternative for general lighting, the market demand for higher brightness, higher efficiency and lower costs was the motivation for improving the LED technology. Locking in on the LED manufacturing process, most steps are on die-level after chip singularizing and therefore the costs are dominated by the huge number of dies which could often reach several thousand dies on one wafer. It's obvious that WLP has a clear benefit for LED packaging and it is also the path to success for LED manufacturing. Moreover, it also allows the implementation and integration of additional functionalities to the LED chip module, e.g. electrical connects, Zener-Diode, mirrors, optics drivers etc. Nonetheless, a clear important aspect to adopt WLP for LED manufacturing is to benefit from existing know-how of the IC manufacturing technology and of the experience of the equipment suppliers for this industry. However, the equipment needs to be optimized for the dedicated LED-WLP application. For exa...