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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