June 5, 2013…The US. Department of Energy has announced the selection for Round 4 of funding for its SSL Manufacturing R&D Projects. The DOE selected five projects to receive the funding. The funding is in response to the SSL Manufacturing R&D funding opportunity announcement (FOA) DE-FOA-0000792. The two-year projects, which will be granted $10.1 million total from the DOE to be matched by the five companies, will focus on achieving significant cost reductions while maintaining quality by improving manufacturing equipment, processes, or monitoring techniques. These efforts are part of DOE’s initiative to accelerate the adoption of SSL technology and encourage US.-based manufacturing of SSL technologies.The selections are described below (final details are subject to negotiations).
Cree of Durham, North Carolina USA, will receive funding for its project titled ”Scalable Light Module for Low‐Cost, High Efficiency LED Luminaires”. Cree’s project is to develop a versatile, low-cost, low-profile LED light-module architecture that facilitates the assembly of a variety of high-efficacy, broad-area LED luminaires. The light module will be driven by a novel, compact LED package for a combination of high color rendering index (CRI) and high efficacy over a wide range of color temperatures. Cree plans to take a vertically integrated approach to the development of the LED component and light module, optical, electrical, and mechanical sub-systems for optimal light generation, distribution, extraction, and diffusion.
Eaton Corporation based in Menomonee Falls, Wisconsin USA, will receive funding for its proposed project titled, “Print‐Based Manufacturing of Integrated, Low Cost, High Performance SSL Luminaires”. For this project, Eaton plans to reduce costs by using manufacturing process innovation to develop a way to place the LED package, chip, or chip arrays directly on a fixture or heatsink. Eaton will develop non-traditional thick-film processes to investigate the use of flexible manufacturing for planar, non-planar, and recessed product designs. According to the project proposal, the approach will include the placement of integrated power electronics and will allow for cost reductions through improved thermal performance, reduced materials and parts, and enabled automation and manufacturing flexibility.
OLEDWorks, LLC of Rochester, New York USA, will receive funding for its proposed project titled, “Innovative High‐Performance Deposition Technology for Low‐Cost Manufacturing of OLED Lighting”. For this project OLEDWorks hopes to reduce OLED manufacturing costs by developing innovative high-performance deposition technology. The proposed deposition technology provides will in theory solve the two largest parts of the OLED lighting manufacturing cost problem: the expense of organic materials per area of useable product, and the depreciation of equipment. The goal is to be able to supply affordable, high-quality OLED lighting products to help grow the emerging OLED lighting market.
Philips Lumileds Lighting Company will receive funding for its proposed project titled, “Development and Industrialization of InGaN/GaN LEDs on Patterned Sapphire Substrates for Low Cost Emitter Architecture”. According to the project proposal, Philips Lumiles hopes to reduce LED manufacturing costs by establishing a patterned sapphire substrate fabrication process with demonstrated epitaxial growth of indium gallium nitride (InGaN) layers capable of producing high-efficiency LEDs when combined with chip-on-board packaging techniques. The company hopes to eliminate some of the complex processes associated with current flip-chip technology and enable lower-cost packaging methods that take advantage of the stability of the sapphire substrate, which is removed in a standard flip-chip device. Philips Lumileds asserts in the project proposal that this approach has the potential to reduce the cost of high-brightness LED lamps and modules targeted across a wide range of lighting and illumination applications.
PPG Industries, Inc. of Pittsburgh, Pennsylvania USA will receive funding for its proposed project titled, “Manufacturing Process for OLED Integrated Substrate”. For the project PPG plans to develop manufacturing processes to enable commercialization of a large-area, low‐cost “integrated substrate” for rigid OLED lighting, using inexpensive float glass combined with a transparent conductive anode film layer, and internal and external light extraction techniques. The company contends that the availability of a commercial, low‐cost substrate will reduce manufacturing costs of the OLED devices to stimulate marketable product developments and provide a technology base for increased OLED manufacturing capacity as demand grows.