Light Management Technology Migration: Displays to General Illumination

Tom Simpson 3M Display & Graphics Business Laboratory

Displays General Lighting

Heat Management

Light Management

Light Sources

Form Factor

Flat Panel Displays (Cumulative Units 1995 - 2011)

1996 1998 2000 2002 2004 2006 2008 20100

100x103

200x103

300x103

400x103

500x103

600x103

700x103

800x103

900x103

1x106

1x106

1x106

1x106

1x106

2x106

2x106

LCD Monitor MD Projection Digital Signage LCD TV Plasma TV Smartphone Photo Frame iPod eBook Near to Eye Wii Netbook iPhone Pico Connected TV iPad 3D TV

100

200

300

400

500

700

600

800

900

1,000

1,100

1,200

1,300

1,500

1,400

1,600

0

Mill

ions

of U

nits

LCD Monitor

LCD TV

Smartphone

iPod

17 FPD Platforms (Market Entry after 1995)

Sources: DisplaySearch, Apple, Nintendo, Gartner, Pacific Media

LED Adoption in LCD TV

Source: DisplaySearch

TV Units (2004- 2014)

Cost Trajectory for LED Luminaires

Hendy Consulting, 2011

Displays: LED Incubator • LED dominate form of LCD backlight by end of 2012 • ~100 billion dies incorporated into LCD TV backlights by 2014 • Allowing:

– Huge capacity build-out. . . . – Increased wafer sizes and higher utilization rates . . . . – Dramatic decreases in HB die prices and improved performance . . . .

• Enabling LED migration into general lighting.

Lighting Attributes Cost

Installed Manufacturing cost Operational Efficiency

Reliability LED and ancillary components

Performance Color

Brightness Spatial distribution Angular distribution

How do we go after all of that?

Capability palette…

Ab Abrasives

Bi Biotech

Ac Acoustics

Ce Ceramics

Ad Adhesives

Dd Drug

Delivery

Am Advanced Materials

Di Display

An Analytical

Do Dental &

Orthodontic Materials

As Application Software

Ec Energy

Components

Em Electronic Materials

Fc Flexible

Converting & Packaging

Fe Flexible

Electronics

Fs Filtration,

Separation, Purification

Fi Films

Im Imaging

Fl Fluoro-

materials

In Inspection &

Measure-ment

Is Integrated Systems &

Design

Lm Light Mgmt

Md Medical

Data Mgmt

Me Metal Matrix Composites

Mf Mechanical Fasteners

Mi Microbial

Detection & Control

Mo Molding

Mr Micro-

replication

Pe Predictive

Engineering & Modeling

Nt Nano-

technology

Nw Nonwoven Materials

Rp Radiation Processing

Se Sensors

Po Porous

Materials & Membranes

Pm Polymer

Melt Processing

Wo Wound Mgmt

Vp Vapor

Processing

Su Surface

Modification

Sm Specialty Materials

Op Opto-

electronics

Pd Particle & Dispersion Processing

Pr Process Design & Control

Pp Precision

Processing

Tt Track and

Trace

We Accelerated Weathering

De Design

Hf Human Factors

…applied to lighting

Ab Abrasives

Bi Biotech

Ac Acoustics

Ce Ceramics

Ad Adhesives

Dd Drug

Delivery

Am Advanced Materials

Di Display

An Analytical

Do Dental &

Orthodontic Materials

As Application Software

Ec Energy

Components

Em Electronic Materials

Fc Flexible

Converting & Packaging

Fe Flexible

Electronics

Fs Filtration,

Separation, Purification

Fi Films

Im Imaging

Fl Fluoro-

materials

In Inspection &

Measure-ment

Is Integrated Systems &

Design

Lm Light Mgmt

Md Medical

Data Mgmt

Me Metal Matrix Composites

Mf Mechanical Fasteners

Mi Microbial

Detection & Control

Mo Molding

Mr Micro-

replication

Pe Predictive

Engineering & Modeling

Nt Nano-

technology

Nw Nonwoven Materials

Rp Radiation Processing

Se Sensors

Po Porous

Materials & Membranes

Pm Polymer

Melt Processing

Wo Wound Mgmt

Vp Vapor

Processing

Su Surface

Modification

Sm Specialty Materials

Op Opto-

electronics

Pd Particle & Dispersion Processing

Pr Process Design & Control

Pp Precision

Processing

Tt Track and

Trace

We Accelerated Weathering

New Lighting Capabilities Build On New Connections

De Design

Hf Human Factors

Challenges & Opportunities

• Heat Management – Lifetime – Reliability – Efficiency

• Light Management – Efficiency – Quality – Form Factor

Heat Management: Primary Thermal Effects

LCD • Response time • Contrast • Reliability/Service Life

LED • Forward voltage • Total Luminous Flux • Efficacy (lm/W) • Spectral output • Reliability/Service Life

Heat Mgmt Technology Migration Displays to Lighting

LCD heat management Internal unseen components (e.g. heat sinks, heat

pipes, fans…)

Lighting systems Heat rejection from external surfaces

Optimized lighting system design thermal + optical + aesthetic co-design

Heat Transfer

heated surface

gravity vector

temperature profile

velocity profile

cool fluid

warm fluid

Switch

Convection Radiation

heated surface

surroundings

Surface-to-surface process •net exchange of ≈ 3 to 30 µm radiation

Depends on • Surface area &

geometry • Delta T • Surface emissivity

Performance and Aesthetics

iGuzzini illuminazione Archilede LED street-lighting system

Emissivity typical values highly polished metals < 0.05

roughened metals < 0.30

heavily oxidized metals > 0.60

anodic coatings > 0.75

most plastics > 0.85

most paints > 0.85

Aesthetics of surface can directly impact thermal performance!

Thermal / Optical / Aesthetic Co-Design

Jake Dyson Products http://www.jakedyson.com/media/downloads/brochures/csys_brochure.pdf

Light Management

Backlit LCDs: Light Guides Spatial uniformity Optical efficiency

Luminaires: Extreme variability Reflectors Refractors Diffusers Filters Light Guides, …

Brightness Distribution

Angular Spatial

Spectrum

Backlight Architectures

Back Reflector Extraction Features (e.g. white dots) Light Guide (with mirrored edges) Diffuser Sheet Enhancement Enhancement

Reflective Source Cavity

LEDs

Mirror Lining

Polarizer

Enhancement

Cavity Lining

Diffuser Plate

Enhancement

Enhancement

LED Clusters 1 1.5

Edge-Lit Solid (<8mm)

Direct Lit Hollow (<25 mm)

Edge-Lit Hollow (<12mm)

Bead Coating

Advances in LCDs Enabled by LED Backlights

• Thinner – Edge-lit backlights

• More Efficient – Increasing source efficacy – Field sequential color (RGB)

• Cost Down • More Appealing

– Increased gamut (RGB) – Zonal-control backlights / High-dynamic-range

Injection

HB LED TV Small footprint HB

Notebook Monitor TV 2005------------------------2010

High flux density Edge injection Thin Backlights Thin bezels BUT… Uniformity challenge (headlighting) uniformity components appearing edge architecture tapes

Luminaire Design Flexibility

Transport

• Light guide advancements – Thickness – Uniformity – Efficiency

• Solid Light Guides – TIR: “loss-less” bounces – Materials: low absorbance, low scattering – Thinnest option, defined by:

• Path length (absorbance) • Degree of collimation

• Hollow Light Guides – Efficient bounces (not lossless) – Thin, defined by:

• Degree of collimation • Efficiency & number of bounces

Luminaire Design Flexibility

Extraction

• Final arbiter of uniformity – Spatial—brightness uniformity

• TV ~90% uniformity • Luminaires <~70% uniformity

– Angular control TV Monitor Luminaire Vertical narrow narrow situational Horizontal wide narrow situational Directional control in luminaires • Uniform • Designed nonuniform • Mitigated glare • Efficiency

Luminaire Design Flexibility

Display Components additive effects

• Collimation control – Glare – Cut-off angle – Efficiency

• Polarization control – Glare – Aesthetics

• Color control – Aesthetics – Functional

Hollow Light Guides

Solid Light Guides

Oree

OLED vs. LED

Display Lighting

Efficiency OLED LED Emissive vs. transmissive, contrast

Cost LED LED Display: OLED approaching?

Lifetime LED LED OLED lifetime ~ display lifetime

Form factor: planar OLED OLED/LED OLED thinner, inherently “planar”

Form factor: point n/a LED

OSRAM

OLED Cost Trajectory, $/m2

DoE Estimate

OLED Penetration

Canaccord Genuity

Displays: OLED Incubator Display demand enabling OLEDs….

Cost down: scale, process improvement Efficiency up: extraction, materials improvement Lifetime up: barrier improvement

….but LEDs have (insurmountable?) head start. Cost: competitive in displays; not in lighting Efficiency : winner in displays; behind in lighting Lifetime: sufficient for displays; marginal for lighting

OLED Offerings 2011

Hendy Consulting, 2011

Displays General Lighting

LED cost down, performance up…. …enabling entry into general lighting Light guide technology developed… …applicable to planar luminaires OLED cost down, performance up LED presents challenging & moving target to OLED