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DOE OSTI2015

Semiconductor nanocrystal quantum dot synthesis approaches towards large-scale industrial production for energy applications

This study reviews the experimental synthesis and engineering developments that focused on various green approaches and large-scale process production routes for quantum dots. Fundamental process engineering principles were illustrated. In relation to the small-scale hot injection method, our discussions focus on the non-injection route that could be scaled up with engineering stir-tank reactors. In addition, applications that demand to utilize quantum dots as "commodity" chemicals are discussed, including solar cells and solid-state lightings.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

High external quantum efficiency (6.5%) InGaN V-defect LEDs at 600 nm on patterned sapphire substrates

Highly efficient long-wavelength InGaN LEDs have been a research focus in nitride LEDs for their potential applications in displays and solid-state lighting. A key breakthrough has been the use of laterally injected quantum wells via naturally occurring V-defects which promote hole injection through semipolar sidewalls and help to overcome the barriers to carrier injection that plague long wavelength nitride LEDs. In this article, we study V-defect engineered LEDs on (0001) patterned sapphire substrates (PSS) and GaN on (111) Si. V-defects were formed using a 40-period InGaN/GaN superlattice and we report a packaged external quantum efficiency (EQE) of 6.5% for standard 0.1 mm 2 . LEDs on PSS at 600 nm. We attribute the high EQE in these LEDs to lateral injection via V-defects.

Ewing, Jacob J.↗

DOE OSTI2022

Materials research and development needs to enable efficient and electrified buildings

Because of the complexity of modern buildings—with many interconnected materials, components, and systems—fully electrifying buildings will require targeted R&D and efficient coordination across those material, component, and system levels. Because buildings that consume the smallest amount of energy are easier to electrify, energy efficiency is a crucial step toward fully electrified buildings. Materials advances will play an important role in both reducing the energy intensity of buildings and electrifying their remaining energy use. Materials are currently being explored, discovered, synthesized, evaluated, optimized, and implemented across many building components, including solid-state lighting; dynamic windows and opaque envelopes; cold climate heat pumps; thermal energy storage; heating, ventilating, and air conditioning (HVAC); refrigeration; non-vapor compression HVAC; and more. In this article, we review the current state-of-the-art of materials for various buildings end uses and discuss R&D challenges and opportunities for both efficiency and electrification.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2011

MATERIALS DEGRADATION ANALYSIS AND DEVELOPMENT TO ENABLE ULTRA LOW COST, WEB-PROCESSED WHITE P-OLED FOR SSL

Progress over Phase II of DE-FG02-07ER86293 'Materials Degradation Analysis and Development to Enable Ultra Low Cost, Web-Processed White P-OLED for SSL' was initially rapid in terms of device performance improvements. We exceeded our device luminance lifetime goals for printed flexible white OLEDs as laid out in our project proposal. Our Phase II performance target was to demonstrate >1500 hours luminance lifetime at 100 Cd/m2 from a printed flexible device. We now have R&D devices well in excess of 8000 hrs lifetime at 100 Cd/m2, tested in air. We also were able to produce devices which met the voltage target of >1500 hours below 15V operation. After completing the initial performance milestones, we went on to focus on color-related degradation issues which were cited as important to commercialization of the technology by our manufacturing partners. We also put additional focus on cathode work as the active material development that occurred over the STTR time period required an adaptation of the cathode from the original cathode formulations which were developed based on previous generation active layer materials. We were able to improve compatibility of the cathode with some of the newer generation active layer materials and improve device yield and voltage behavior. An additional objective of the initial Phase II was to further develop the underlying manufacturing technology and real-life product specifications. This is a key requirement that must be met to ensure eventual commercialization of this DOE-funded technology. The link between commercial investment for full commercialization and R&D efforts in OLED solid State Lighting is often a large one. Add-Vision's lower cost, printed OLED manufacturing approach is an attraction, but close engagement with manufacturing partners and addressing customer specifications is a very important link. Manufacturing technology encompasses development of moisture reduction encapsulation technology, improved cost performance, and reductions in operating voltage through thinner and higher uniformity active device layers. We have now installed a pilot encapsulation system at AVI for controlled, high throughput lamination encapsulation of flexible OLEDs in a novel process. Along with this, we have developed, with our materials supply partners, adhesives, barrier films and other encapsulation materials and we are showing total air product lifetimes in the 2-4 years range from a process consistent with our throughput goals of {approx}1M device per month ({approx}30,000 sq. ft. of processed OLEDs). Within the last year of the project, we have been working to introduce the manufacturing improvements made in our LEP deposition and annealing process to our commercial partners. Based on the success of this, a pilot scale-up program was begun. During this process, Add-Vision was acquired by a strategic partner, in no small part, because of the promise of future success of the technology as evidenced by our commercial partners pilot scale-up plans. Overall, the performance, manufacturing and product work in this project has been successful. Additional analysis and device work at LBL has also shown a unique adhesion change with device bias stressing which may result from active layer polymer cross-linking during bias stressing of device. It was shown that even small bias stresses, as a fraction of a full device lifetime stress period, result in measurable chemical change in the device. Further work needs to be conducted to fully understand the chemical nature of this interaction. Elucidation of this effect would enable doped OLED formulation to be engineered to suppress this effect and further extend lifetimes and reduce voltage climb.

36 MATERIALS SCIENCE↗

DOE OSTI2012

Low Cost Lithography Tool for High Brightness LED Manufacturing

The objective of this activity was to address the need for improved manufacturing tools for LEDs. Improvements include lower cost (both capital equipment cost reductions and cost-of ownership reductions), better automation and better yields. To meet the DOE objective of $1-2/kilolumen, it will be necessary to develop these highly automated manufacturing tools. Lithography is used extensively in the fabrication of high-brightness LEDs, but the tools used to date are not scalable to high-volume manufacturing. This activity addressed the LED lithography process. During R&D and low volume manufacturing, most LED companies use contact-printers. However, several industries have shown that these printers are incompatible with high volume manufacturing and the LED industry needs to evolve to projection steppers. The need for projection lithography tools for LED manufacturing is identified in the Solid State Lighting Manufacturing Roadmap Draft, June 2009. The Roadmap states that Projection tools are needed by 2011. This work will modify a stepper, originally designed for semiconductor manufacturing, for use in LED manufacturing. This work addresses improvements to yield, material handling, automation and throughput for LED manufacturing while reducing the capital equipment cost.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2013

Recovery Act: Low-Cost, Highly Lambertian Reflector Composite For Improved LED Fixture Efficiency and Lifetime

The overall objective of the program was to demonstrate a 98% or greater reflective, highly diffuse, low-cost composite material that significantly improves luminaire efficiency, is able to withstand 50,000 hours or greater luminaire operation under expected LED system thermal and environmental operating extremes and meets the cost targets required to be an effective commercial solution for the Solid State Lighting industry. This project met most of the goals defined and contributed to the understanding of high reflectance, white coatings. Research under this program increased the understanding of coatings development using particle size reduction techniques and preparation of coating solutions with a broad range of particle types. The research explored scale-up of coating systems and generated understanding of processing required for high volume manufacturing applications. The work demonstrated how coating formulation and application technique can translate to material durability and LED system lifetime. The research also demonstrated improvements in lighting efficiency to be gained using high reflectance white coatings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2013

Development of Production PVD-AIN Buffer Layer System and Processes to Reduce Epitaxy Costs and Increase LED Efficiency (Final Scientific/Technical Report)

The DOE has set aggressive goals for solid state lighting (SSL) adoption, which require manufacturing and quality improvements for virtually all process steps leading to an LED luminaire product. The goals pertinent to this proposed project are to reduce the cost and improve the quality of the epitaxial growth processes used to build LED structures. The objectives outlined in this proposal focus on achieving cost reduction and performance improvements over state-of-the-art, using technologies that are low in cost and amenable to high efficiency manufacturing. The objectives of the outlined proposal focus on cost reductions in epitaxial growth by reducing epitaxy layer thickness and hetero-epitaxial strain, and by enabling the use of larger, less expensive silicon substrates and would be accomplished through the introduction of a high productivity reactive sputtering system and an effective sputtered aluminum-nitride (AlN) buffer/nucleation layer process. Success of the proposed project could enable efficient adoption of GaN on-silicon (GaN/Si) epitaxial technology on 150mm silicon substrates. The reduction in epitaxy cost per cm 2 using 150mm GaN-on-Si technology derives from (1) a reduction in cost of ownership and increase in throughput for the buffer deposition process via the elimination of MOCVD buffer layers and other throughput and CoO enhancements, (2) improvement in brightness through reductions in defect density, (3) reduction in substrate cost through the replacement of sapphire with silicon, and (4) reduction in non-ESD yield loss through reductions in wafer bow and temperature variation. The adoption of 150mm GaN/Si processing will also facilitate significant cost reductions in subsequent wafer fabrication manufacturing costs. There were three phases to this project. These three phases overlap in order to aggressively facilitate a commercially available production GaN/Si capability. In Phase I of the project, the repeatability of the performance was analyzed and improvements implemented to the Veeco PVD-AlN prototype system to establish a specification and baseline PVD-AlN films on sapphire and in parallel the evaluation of PVD AlN on silicon substrates began. In Phase II of the project a Beta tool based on a scaled-up process module capable of depositing uniform films on batches of 4” or 6” diameter substrates in a production worthy operation was developed and qualified. In Phase III, the means to increase the throughput of the PVD-AlN sy0stem was evaluated and focused primarily on minimizing the impact of the substrate heating and cooling times that dominated the overall cycle time.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2013

Low-Cost Illumination-Grade LEDs

Solid State Lighting is a cost-effective, energy-conserving technology serving a rapidly expand- ing multi-billion dollar market. This program was designed to accelerate this lighting revolution by reducing the manufacturing cost of Illumination-Grade LEDs. The technical strategy was to investigate growth substrate alternatives to standard planar sapphire, select the most effective and compatible option, and demonstrate a significant increase in Lumen/$ with a marketable LED. The most obvious alternate substrate, silicon, was extensively studied in the first two years of the program. The superior thermal and mechanical properties of Si were expected to improve wavelength uniformity and hence color yield in the manufacture of high-power illumination- grade LEDs. However, improvements in efficiency and epitaxy uniformity on standard c-plane sapphire diminished the advantages of switching to Si. Furthermore, the cost of sapphire decreased significantly and the cost of processing Si devices using our thin film process was higher than expected. We concluded that GaN on Si was a viable technology but not a practical option for Philips Lumileds. Therefore in 2012 and 2013, we sought and received amendments which broadened the scope to include other substrates and extended the time of execution. Proprietary engineered substrates, off-axis (non-c-plane) sapphire, and c-plane patterned sapphire substrates (PSS) were all investigated in the final 18 months of this program. Excellent epitaxy quality was achieved on all three candidates; however we eliminated engineered substrates and non-c-plane sapphire because of their higher combined cost of substrate, device fabrication and packaging. Ultimately, by fabricating a flip-chip (FC) LED based upon c-plane PSS we attained a 42% reduction in LED manufacturing cost relative to our LUXEON Rebel product (Q1-2012). Combined with a flux gain from 85 to 102 Lm, the LUXEON Q delivered a 210% increase in Lm/$ over this time period. The technology was commercialized in our LUXEON Q product in Sept., 2013. Also, the retention of the sapphire increased the robustness of the device, enabling sales of low-cost submount-free chips to lighting manufacturers. Thus, blue LED die sales were initiated in the form of a PSS-FC in February, 2013.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2013

High Efficiency Integrated Package

Solid-state lighting based on LEDs has emerged as a superior alternative to inefficient conventional lighting, particularly incandescent. LED lighting can lead to 80 percent energy savings; can last 50,000 hours – 2-50 times longer than most bulbs; and contains no toxic lead or mercury. However, to enable mass adoption, particularly at the consumer level, the cost of LED luminaires must be reduced by an order of magnitude while achieving superior efficiency, light quality and lifetime. To become viable, energy-efficient replacement solutions must deliver system efficacies of ≥ 100 lumens per watt (LPW) with excellent color rendering (CRI > 85) at a cost that enables payback cycles of two years or less for commercial applications. This development will enable significant site energy savings as it targets commercial and retail lighting applications that are most sensitive to the lifetime operating costs with their extended operating hours per day. If costs are reduced substantially, dramatic energy savings can be realized by replacing incandescent lighting in the residential market as well. In light of these challenges, Cree proposed to develop a multi-chip integrated LED package with an output of > 1000 lumens of warm white light operating at an efficacy of at least 128 LPW with a CRI > 85. This product will serve as the light engine for replacement lamps and luminaires. At the end of the proposed program, this integrated package was to be used in a proof-of-concept lamp prototype to demonstrate the component’s viability in a common form factor. During this project Cree SBTC developed an efficient, compact warm-white LED package with an integrated remote color down-converter. Via a combination of intensive optical, electrical, and thermal optimization, a package design was obtained that met nearly all project goals. This package emitted 1295 lm under instant-on, room-temperature testing conditions, with an efficacy of 128.4 lm/W at a color temperature of ~2873K and 83 CRI. As such, the package’s performance exceeds DOE’s warm-white phosphor LED efficacy target for 2013. At the end of the program, we assembled an A19 sized demonstration bulb housing the integrated package which met Energy Star intensity variation requirements. With further development to reduce overall component cost, we anticipate that an integrated remote converter package such as developed during this program will find application in compact, high-efficacy LED-based lamps, particularly those requiring omnidirectional emission.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2014

LOW-COST LED LUMINAIRE FOR GENERAL ILLUMINATION

During this two-year Solid-State Lighting (SSL) Manufacturing R&D project Cree developed novel light emitting diode (LED) technologies contributing to a cost-optimized, efficient LED troffer luminaire platform emitting at ~3500K correlated color temperature (CCT) at a color rendering index (CRI) of >90. To successfully achieve program goals, Cree used a comprehensive approach to address cost reduction of the various optical, thermal and electrical subsystems in the luminaire without impacting performance. These developments built on Cree’s high- brightness, low-cost LED platforms to design a novel LED component architecture that will enable low-cost troffer luminaire designs with high total system efficacy. The project scope included cost reductions to nearly all major troffer subsystems as well as assembly costs. For example, no thermal management components were included in the troffer, owing to the optimized distribution of compact low- to mid-power LEDs. It is estimated that a significant manufacturing cost savings will result relative to Cree’s conventional troffers at the start of the project. A chief project accomplishment was the successful development of a new compact, high-efficacy LED component geometry with a broad far-field intensity distribution and even color point vs. emission angle. After further optimization and testing for production, the Cree XQ series of LEDs resulted. XQ LEDs are currently utilized in Cree’s AR series troffers, and they are being considered for use in other platforms. The XQ lens geometry influenced the independent development of Cree’s XB-E and XB-G high-voltage LEDs, which also have a broad intensity distribution at high efficacy, and are finding wide implementation in Cree’s omnidirectional A-lamps.

Lowes, Ted↗

DOE OSTI2015

Quantitative Electron Nanodiffraction.

This Final report summarizes progress under this award for the final reporting period 2002 - 2013 in our development of quantitive electron nanodiffraction to materials problems, especially devoted to atomistic processes in semiconductors and electronic oxides such as the new artificial oxide multilayers, where our microdiffraction is complemented with energy-loss spectroscopy (ELNES) and aberration-corrected STEM imaging (9). The method has also been used to map out the chemical bonds in the important GaN semiconductor (1) used for solid state lighting, and to understand the effects of stacking sequence variations and interfaces in digital oxide superlattices (8). Other projects include the development of a laser-beam Zernike phase plate for cryo-electron microscopy (5) (based on the Kapitza-Dirac effect), work on reconstruction of molecular images using the scattering from many identical molecules lying in random orientations (4), a review article on space-group determination for the International Tables on Crystallography (10), the observation of energy-loss spectra with millivolt energy resolution and sub-nanometer spatial resolution from individual point defects in an alkali halide, a review article for the Centenary of X-ray Diffration (17) and the development of a new method of electron-beam lithography (12). We briefly summarize here the work on GaN, on oxide superlattice ELNES, and on lithography by STEM.

36 MATERIALS SCIENCE↗

DOE OSTI2015

DC Microgrids Scoping Study. Estimate of Technical and Economic Benefits

Microgrid demonstrations and deployments are expanding in US power systems and around the world. Although goals are specific to each site, these microgrids have demonstrated the ability to provide higher reliability and higher power quality than utility power systems and improved energy utilization. The vast majority of these microgrids are based on AC power transfer because this has been the traditionally dominant power delivery scheme. Independently, manufacturers, power system designers and researchers are demonstrating and deploying DC power distribution systems for applications where the end-use loads are natively DC, e.g., computers, solid-state lighting, and building networks. These early DC applications may provide higher efficiency, added flexibility, reduced capital costs over their AC counterparts. Further, when onsite renewable generation, electric vehicles and storage systems are present, DC-based microgrids may offer additional benefits. Early successes from these efforts raises a question - can a combination of microgrid concepts and DC distribution systems provide added benefits beyond what has been achieved individually?

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2015

Manufacturing Demonstration Facility: Low Temperature Materials Synthesis

The Manufacturing Demonstration Facility (MDF) low temperature materials synthesis project was established to demonstrate a scalable and sustainable process to produce nanoparticles (NPs) for advanced manufacturing. Previous methods to chemically synthesize NPs typically required expensive, high-purity inorganic chemical reagents, organic solvents and high temperatures. These processes were typically applied at small laboratory scales at yields sufficient for NP characterization, but insufficient to support roll-to-roll processing efforts or device fabrication. The new NanoFermentation processes described here operated at a low temperature (~60 C) in low-cost, aqueous media using bacteria that produce extracellular NPs with controlled size and elemental stoichiometry. Up-scaling activities successfully demonstrated high NP yields and quality in a 900-L pilot-scale reactor, establishing this NanoFermentation process as a competitive biomanufacturing strategy to produce NPs for advanced manufacturing of power electronics, solid-state lighting and sensors.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2017

Impacts of the EISA 2007 Energy Efficiency Standard on General Service Lamps

The Energy Policy and Conservation Act of 1975, as amended by the Energy Independence and Security Act of 2007 (EISA 2007), requires that, effective beginning January 1, 2020, the Secretary of Energy shall prohibit the sale of any general service lamp (GSL) that does not meet a minimum efficacy standard of 45 lumens per watt. This is referred to as the EISA 2007 backstop. The U.S. Department of Energy recently revised the definition of the term GSL to include certain lamps that were either previously excluded or not explicitly mentioned in the EISA 2007 definition. For this subset of GSLs, we assess the impacts of the EISA 2007 backstop on national energy consumption, carbon dioxide emissions, and consumer expenditures. To estimate these impacts, we projected the energy use, purchase price, and operating cost of representative lamps purchased during a 30-year analysis period, 2020-2049, for cases in which the EISA 2007 backstop does and does not take effect; the impacts of the backstop are then given by the difference between the two cases. In developing the projection model, we also performed the most comprehensive assessment to date of usage patterns and lifetime distributions for the analyzed lamp types in the United States. There is substantial uncertainty in the estimated impacts, which arises from uncertainty in the speed and extent of the market conversion to solid state lighting technology that would occur in the absence of the EISA 2007 backstop. In our central estimate we find that the EISA 2007 backstop results in significant energy savings of 27 quads and consumer net present value of $120 billion (at a seven percent discount rate) for lamps shipped between 2020 and 2049, and carbon dioxide emissions reduction of 540 million metric tons by 2030 for those GSLs not explicitly included in the EISA 2007 definition of a GSL.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2016

High efficiency and stable white OLED using a single emitter

The ultimate objective of this project was to demonstrate an efficient and stable white OLED using a single emitter on a planar glass substrate. The focus of the project is on the development of efficient and stable square planar phosphorescent emitters and evaluation of such class of materials in the device settings. Key challenges included improving the emission efficiency of molecular dopants and excimers, controlling emission color of emitters and their excimers, and improving optical and electrical stability of emissive dopants. At the end of this research program, the PI has made enough progress to demonstrate the potential of excimer-based white OLED as a cost-effective solution for WOLED panel in the solid state lighting applications.

47 OTHER INSTRUMENTATION↗

DOE OSTI2015

University of Maryland Wall Washer Retrofit - LED Modules Replace Halogen Lamps in a Performing Arts Center

The University of Maryland (UMD) began retrofitting halogen wall washers in the Clarice Smith Performing Arts Center (CSPAC) in April 2014. The U.S. Department of Energy (DOE) Solid-State Lighting (SSL) GATEWAY program documented this process through the final installation in March 2015, summarized in this report. The wall washers illuminate hallways lining the atrium, providing task illuminance for transitioning between spaces and visual interest to the atrium boundaries. The main goals of the retrofit were to maintain the visual appearance of the space while reducing maintenance costs – energy savings was considered an additional benefit by UMD Facilities Management. UMD Facilities Management is pleased with the results of this retrofit, and continues to initiate LED retrofit projects across the UMD campus.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Impact of the EISA 2007 Energy Efficiency Standard on General Service Lamps

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2018

Scalable processing of ZnS nanoparticles for high photoluminescence efficiency quantum dots

Nano Elements Source, LLC, a biotech startup has licensed the NanoFermentation technology from Oak Ridge National Laboratory to further commercialize low cost, cadmium free photoluminescent nanoparticles produced using affordable, environmentally-friendly. This project aimed to develop post chemical processing of biosynthesized ZnS quantum dots (QD) to improve their efficiency of luminescence to make them suitable for solid state lighting applications. Several post processing approached were proposed and tested using to biosynthesized of ZnS QD. Optical properties of ZnS nanoparticles including soft chemical etching, and photonic etching have been tested and quantified against standard materials. We applied the developed chemical modification approach to control quality of chemically synthetized ZnS QD’s, and to calculate the maximum achievable efficiency of photoluminescence. We estimated the cost of the proposed post-processing treatment of nanoFermented nanoparticles and proposed several approaches to further the development of low cost nanoparticles for electro-optical and other applications relevant to DOE mission.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗