"If circle LEDs are the next thing be prepared to pay more for them as specialized equipment will be needed for singulation and the usable area for die drops significantly due to wasted material". Again....., no, not really. Currently used lasers make round shapes just as easy as square shapes. The only thing close to accurate in this statement is the (very) slightly increased wasted space per die. They might be a tiny bit more expensive but not much. As soon as another producer starts making them the price will drop. Heck, the price drops every year for square ones just because the volume of production goes up. Right? This is a common sense thing.
I forsee/predict a prefocused round LED that will eliminate the need for any kind of reflector whatsoever. Smaller, lighter, cheaper.
Umm, I can go over right now and see the Diamond Dicing saws at work right now if I want. Guess what they are basically circular saws, they are not lasers.
Trust me, I know how LEDs are made, I am sure I know a lot more on how LEDs are made than you, I make them myself. If you want I can educate you on the process.
True. The part about waste is not going to change though. If you draw a grid of circles, 1 circle will touch its 4 nearest neighbors on 4 infinitely small points. In between all the connections will be a small cross of wasted scrap material that can’t be used.
Bose301s (mr. know it all) - try watching the link I posted and learn something. I can post three more from different makers of LEDs that show virtually the same thing. You want them? Saws? Really? Oh, hell no. You must be going to Fred Flintstone's LED Cave to watch something like that. I imagine folks are lining up at your door to buy your homemade LEDs. What does it cost you to do gallium arsenide deposits on the metal substrate? What class of clean room do you use? Do you even know that clean rooms come in different flavors (classes)? You must be very rich to have all this wonderful equiptment? I'm pretty sure you might know something I don't but I'm equally sure I have no interest in learning how to pick my nose in a new way. Only 16 posts and already I have some clown (Nyah nyah, I know more than you do) climbing up my butt and resorting to personal insults. Is that the best you can do, smart guy? Lame at best. I posted the link for all to see but I guess nobody bothered to look at it. Maybe you should have.
As I said before, yes, there is more waste. You were right about that. Sort of a no brainer observation though. Congrats!
Again I don’t need to watch your link as I work in the industry, and again, I have seen with my own 2 eyes the dicing saws.
Lol, so much bad info in that post it's not even funny. Gallium Arsenide is for Red LEDs, blue LEDs are InGaN or GaN. LEDs are generally grown on Sapphire or Silicon Carbide wafers, not a metal.
I work in a class 1000 clean room, but we also have class 10,000 and 100 based on the needs of that particular manufacturing step. Obviously you have a slight knowledge of this stuff, but not very much, and definitely not as much as you think you do.
What a suprise! You are obviously a smart guy - maybe. For all I know, you are the janitor there. To smart to watch the video and see how others do it, eh? Or just to smug? I'm aware that different materials are used for different types of product. I saw no reason to write a book to include all the possibilities. Resorting to personal attacks because you got your feelings hurt is not smart at all. I have no idea who you work for and I don't want to know, but I can say with confidence that if you guys are currently using saws to cut out individual LEDs - you either wont be for long or you will be out of business soon. NONE of the big 4 use anything but lasers for their new products. Check it out for yourself. Do some homework and broaden your horizions. The LED industry does not start and end at your place of employment.
I don't really care about waste or cutting them in the most efficient method, they could even make individual bases for them to sit on for all I care instead of cutting them out, that would waste nothing. I would just prefer the most efficient flashlight, not the most efficient for the manufacturer to produce.
This is a pretty poor paint picture but the idea is good, traditional square led on the left and round led on the right. I'm sure all that extra area will produce a lot more lumens.
And if you want to maximise throw instead of basic luminous efficiency then a smaller die with the same current (assuming similar efficiency per unit of area) will give much higher surface brightness..
