Gallium Nitride (GaN) substrates
The substrate must process is broken down into four stages. The substrate must first obtained or produced, which provides support and an atomic pattern for the thin device layers (which generate the light) that are deposited on it.
During a multi-step device fabrication process the device layer-coated substrate is processed and divided into thousands of discrete devices, or dies, that are only a few hundredths of an inch across. Up to 2,000 laser diodes or 10,000-15,000 HB-LED Dies fit onto a single two-inch diameter substrate.
These discrete dies are then packaged, a process that includes mounting the dies to heat sinks, affixing electrical leads, and encasing the dies in transparent protective epoxy.
Its All in the Substrate
Of the four stages in the LED and laser diode value chain, the latter three are well understood from conventional semiconductor processing. GaN substrate technology, on the other hand, is sorely deficient and is the fundamental cause of most current device weaknesses.
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While some techniques are available to reduce these defects densities to tolerable levels, high-end devices require low defect densities that only GaN substrates can practically offer. Expansion of the GaN-based device market will therefore be fundamentally limited by inadequate performance and low manufacturing yields Until high-quality GaN substrates are widely available at modest prices.
These and other lighting applications have created a multi-billion-dollar market for what are known as "high-brightness LEDs" (HB-LEDs):
Blue and green keypad lights and white display backlights in cellular phones are made with bright, energy-efficient GaN LEDs are commonly replacing fragile, inefficient incandescent lamps in traffic signals, saving municipalities millions of dollars annually in Energy and replacement costs.
White GaN LED flashlights last hundreds of hours powered only by simple AA or watch batteries.
Full-color electronic billboards use GaN LEDs for bright blue and green pixels that last the life of the billboard.
Next generation Blu-Ray DVD devices depend on blue laser technology. Current laser diode production processes are still suffering from inadequate GaN substrate material quality. © Copyright 2009 Inlustra Technologies, Inc. All rights reserved. Click here to read our Terms of Use.
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