From the early days of quantum dot (QD) research, QDs have long been targeted for use as downconverters in LEDs due to their combination of unique emission characteristics: tunability of wavelength and narrow emission linewidths [
Photonics Research, Volume. 5, Issue 2, A13(2017)
Exploring the bounds of narrow-band quantum dot downconverted LEDs
Quantum dots are finding increasing commercial success in LED applications. While they have been used for several years in remote off-chip architectures for display applications, it is shown for the first time to our knowledge that quantum dots can withstand the demands of the on-chip architecture and therefore are capable of being used as a direct phosphor replacement in both lighting and display applications. It is well known that, to achieve improved color metrics in lighting as well as increased gamut in display technologies, it is highly desirable to utilize a downconverter with a narrow emission linewidth as well as a precisely tunable peak. This paper will discuss the results of on-chip use of quantum dots in a lighting product, and explore the opportunities and practical limits for improvement of various lighting and display metrics by use of this unique downconverter technology.
1. INTRODUCTION
From the early days of quantum dot (QD) research, QDs have long been targeted for use as downconverters in LEDs due to their combination of unique emission characteristics: tunability of wavelength and narrow emission linewidths [
Downconverters must generally be capable of being applied directly onto the LED chip to allow for a cost-effective device architecture without altering the small form factor achieved by the state-of-the-art LED solutions. Until now, this has presented a major problem for the use of QDs for two key reasons: stability at high temperatures and self-absorption due to a large overlap between absorption and emission by typical QD materials. These issues have been solved through a QD design that directly addresses the issue of stability and self-absorption without incurring any penalty to QD performance. Importantly, QDs are produced in a powder form, thereby addressing a more subtle but definitely not trivial issue of integrating QDs into the LED production process. Specifically, QD powders are added at a sufficiently high level to achieve a desired color point in a way that is compatible with optical grade silicones.
The QDs in this study utilize an architecture that minimizes self-absorption across a range of visible wavelengths (Fig.
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Figure 1.QD absorption and emission spectra for an ensemble of QDs diluted in cyclohexane. These QDs have been engineered to minimize self-absorption, i.e., emission and absorption spectra have minimal overlap. Note that the peak emission has been normalized to the absorption at 450 nm.
Figure 2.Data obtained from Lumileds showing the high temperature operating lifetime (HTOL) of white QD-converted LEDs. LED lighting packages (3535) are aged at a drive current of 200 mA at 95°C. The color maintenance specification set by the DOE Energy Star program is identified with a dashed line.
Like all narrow-emission, high-performance QDs, these QDs contain a small amount of cadmium. The amount of Cd used in the on-chip solution is significantly less than in a remote implementation. However, there is still a desire to evaluate cadmium-free QDs for on-chip use. The most well-developed Cd-free QD candidate technology currently is InP based [
The use of Cd in electronic devices is regulated in the European Union (EU) under the Restriction of Hazardous Substances Directive, or RoHS, and many other countries implement the same regulation with the same limits and exemptions as the EU. The use of Cd is limited to 100 ppm in the smallest homogeneous component of the electronic device containing the metal, which in the case of on-chip LED usage is the downconversion layer composed of silicone, QDs, and other phosphors deposited inside the LED package. In this layer, the QD downconverters are much more concentrated than they would be in a remote optic; therefore, while the total amount of Cd used per LED is a few micrograms, the concentration is currently above 100 ppm for the on-chip QD materials presented here. The actual concentration of Cd depends on the package, color point, and other factors, but currently ranges between 150 and 500 ppm as measured by LED manufacturing partners using these QD materials, as well as by external labs. Currently there is an exemption in place (Exemption 39 of the RoHS Directive) which allows for the use of Cd above the 100 ppm limit in LED applications. The exemption is up for renewal and there is likely to be a revision to the language of the exemption in 2017.
By focusing on on-chip solutions, the range of market opportunities for QDs is greatly expanded. On-chip QD converted LEDs allow for applications in both display and lighting, where the price and configuration of LED bulbs prohibits QD solutions that rely on expensive hermetic seals. Furthermore, on-chip QD converted LEDs do not require additional bulky films or light bars that can potentially prohibit their use in certain applications such as mobile displays, where thin designs are highly desired. Lighting and display applications have somewhat unique challenges, so each one is discussed separately later. Since the tunability of QDs is well established and covers the entire visible spectrum [
2. QUANTUM DOTS FOR ON-CHIP USE
The particles used in this study are cadmium-based core/shell nanocrystals and are made in a multi-step synthetic process. Specifically, several rounds of high-temperature air-free synthesis are used to make CdSe cores followed by multiple semiconductor layers. Subsequently, the QDs are coated with an inorganic barrier layer, which results in a powder as the final form of the material used for on-chip LEDs. Note that at this stage, the QDs are now found in aggregates. Thus, it is no longer possible to assess semiconductor properties such as absorption because scattering greatly overwhelms absorption in the extinction signal. Due to this issue, some types of measurements such as absorption (Fig.
Figure 3.Single-particle optical characteristics compared to ensemble. Top Graph: ensemble absorption HWHM of the first exciton peak for CdSe cores. Experimental batches represent attempts to achieve a narrower size distribution of QD cores. Middle Graph: FWHM comparison; single particles (solid bars) range from 7 to 15 nm narrower than ensemble (dashed bars). Bottom Graph: centroid comparison; single particles (solid bars) are typically within a few nm of ensemble measurements in solution (dashed bars), though there exist samples with large discrepancies.
Figure 4.Confirmed single-QD measurements from Production Batch 1 (
Figure 5.Confirmed single-QD measurements from Experimental Batch 2 (
The quantum efficiency (QE) of these QDs is measured at several stages. After the initial QD synthesis, the QE measurements are made as a dilution of QDs into toluene and have QE values as high as 90%. As a QD powder, the emission wavelength shifts only minimally (
The wavelength shifting and emission broadening of QDs at elevated temperatures cannot be ignored as it can lead to dramatic color shifts and have impacts on many color metrics. In this regard, proper design of QD-based LED products should account for anticipated shifts from ambient conditions to operating temperatures. This temperature dependence of wavelength is a fundamental property of semiconductors and thus an inevitable trade-off that must be dealt with when taking advantage of the other benefits afforded by QD materials.
3. SINGLE-PARTICLE EMISSION SPECTRA
In order to ascertain the lower limits of QD emission linewidth, single-particle QD spectra were acquired. An important question is that of the origin of ensemble QD linewidth. Since QD emission wavelengths are size dependent, conventional wisdom dictates that the linewidth arises from the convolution of size heterogeneity and the intrinsic linewidth.
Single QD spectra were acquired from specimens prepared by dropcasting QDs onto glass coverslips. Samples were prepared from a concentrated QD stock solution stored in toluene. To break up aggregates and minimize sampling errors, each stock solution was vortexed for 15 s and sonicated for at least 5 min immediately prior to dilution. Prior to dropcasting, the sample was diluted three times in a 6:1 cyclohexane/decane mixture. All samples were measured at ambient conditions. Due to the sequential nature of single-particle measurements, the time between sample preparation and measurement varies for each single QD measurement. The longest time elapsed for any such measurement was around 5 h. There was no observable trend with time elapsed since sample preparation. Sample selection bias was minimized by imaging a large area and measuring each dot within that area regardless of brightness. Clusters and quenched QDs were discarded during the data analysis phase.
Single-particle data were collected with a
Roughly 60 presumed single dots were measured for each QD batch of interest. Particles were deemed to be single if they met the criteria of having an area ratio of center-peak to side-peaks in the
The single-particle spectra are compared to their ensemble solution-based measurements, as seen in Fig.
There is a distinction made between production batches of QDs and experimental batches. In the experimental batches, a different synthesis recipe for CdSe cores was used that resulted in a narrower ensemble absorption spectrum. The size homogeneity of CdSe QDs can be judged in part by the half-width-half-maximum (HWHM) of the low-energy side of the first absorption peak. These experimental batches have a significantly narrower HWHM (
As seen in Fig.
The median single-particle FWHM is anywhere from 7 to 15 nm narrower than the ensemble FWHM, depending on recipe as seen in Fig.
The conclusion is that multiple mechanisms are responsible for the optical characteristics of our QDs. Core size has a large effect on the final particle wavelength but a smaller effect on the final particle FWHM. Interestingly, in Experimental Batch 2, there are many instances where some confirmed single particles have linewidths that actually exceed the ensemble average.
While collecting the single-particle data, the excited-state lifetime of each QD is also measured. There is a strong linear correlation (
Early reports of single QDs showed that fluorescence intermittency is correlated to spectral shifts. These shifts were attributed to a quantum-confined Stark effect wherein electric fields due to QD charging are responsible for shifts in wavelength on the timescale of seconds [
The cause of the concomitant increase in Centroid, FWHM, and Lifetime can most easily be attributed to the presence of defect states that lie within the band gap. Recombination from these lower-energy sites would naturally lead to redshifted emission, and a multiplicity of states can account for increased FWHM. As this could be attributed to either electron or hole defect sites, further studies wherein CdSe seeds are directly studied in a different matrix are proposed.
Some strategies for arriving at narrow FWHM QD samples focus on making a homogenous size distribution of particles. This can be accomplished through design improvements to synthesis schemes as well as through processing wherein size selection can be performed, albeit at the expense of yield. From these single-particle data, it is clear that arriving at a mono-disperse size population is only part of the strategy for obtaining narrow linewidths of core-shell QDs. As shown here, relatively narrow size distributions of CdSe QD cores do not necessarily result in narrow-emission linewidths of resulting core-shell particles. The FWHM of single-particles can also be relatively large as a result of shell growth. While the mechanism for wide-FWHM core-shell single particles is still under investigation, it is clear that strategies to improve narrow emission must rely also on the quality of the shell growth. Regardless of the differences observed in shell growth or the initial homogeneity of the CdSe cores, the minimum observed FWHM of single particles is only slightly below 20 nm. This means that further changes to minimize QD core size variations and further improvements to applying semiconductor shell layers are unlikely to result in emission linewidths narrower than 20 nm. In this regard, the near-term limit to FWHM of QDs that are robust enough to withstand the rigors of on-chip testing is estimated to be 20 nm.
4. LIGHTING
The narrow bandwidth of QDs is one of the greatest opportunities to improve LED efficacy in lighting as it enables a dramatic improvement in luminous efficacy of radiation (LER). Here, the LER is calculated for a spectrum as the luminous output divided by the radiative output. State-of-the-art red phosphors emit a significant portion of the light at wavelengths where the eye has little sensitivity. In this regard, the red output contributes to the radiative output but only minimally to the luminous output, resulting in lowered LER values for spectra that have a significant fraction of red light. This is especially true for warm-white LEDs with high color-rendering requirements, which put stringent demands on the amount of light emitted in the red wavelength range at the edge of the visible spectrum. Narrow red converters can enable the same chromaticity and color-rendering quality in a spectrum with a high LER only if the emission is tunable. By precisely locating the narrow red emission at the appropriate wavelengths, high-quality light can be achieved while minimizing emission where the eye is not sensitive. For example, at a correlated color temperature (CCT) of 3000 K, color-rendering index (CRI)
Current LEDs used in lighting and display utilize a blue LED emitting in the range of 450 nm with phosphors such as YAGs and nitrides doped with rare-earth metals such as cerium, europium, etc., Commonly, a two-phosphor system is utilized; yellow–green and a red plus the blue LED give an RGB system that can be tuned for a desired white point. For lighting, the highest LERs can be achieved via a combination of narrow emitters [
When striving for more efficient lighting, the quality of the light is paramount. Previous generations of efficient lighting such as fluorescent were often criticized for poor color quality. In this regard, the focus here is on those lighting solutions that meet the highest color standards.
Two different sets of QD-based test devices have been made: one batch targeted to warm white (2871 K) and another targeted to a cooler white CCT (4020 K). These devices were measured at operating conditions; spectra were acquired at 60°C and a 75 mA drive current. The test devices were made from a 3535 LED package courtesy of Lumileds. These packages emit nominally 450 nm blue light. Phosphor powders obtained from Intematix NYAG4355 (for 2800 K devices) or NYAG4156 (for 4000 K devices) plus red QDs were mixed with optical-grade silicone dispensed into the 3535 packages and cured at 150°C for several hours.
The resulting spectra were broken down into their various parts using a multi-peak fitting algorithm to model each component as a collection of six Gaussian curves: the blue LED modeled by two curves, the phosphor modeled by three curves, and the QD emission modeled by a single Gaussian. The total number of blue photons initially output by the LED die was calculated using the known QE for both the phosphor and QD at operating temperature.
Two different computational models have been run based on the test devices. Since the basis spectra for the modeling were acquired at 60°C, the modeling is representative of QDs at operating temperatures. The aim is to ascertain the size of improvements that can be made to lighting efficiency by further optimizing QD emission output characteristics. The modeling is based on the spectra obtained from the actual devices; a fixed-photon simulation was done, meaning that the number of photons as emitted by the LED die was held constant while various inputs were altered. Specifically, the QD emission wavelength FWHM, QE, and loading in addition to the phosphor loading were all varied in this model. In each modeled spectrum, all photons were accounted for, meaning a broadening of FWHM lowered the Gaussian peak (for a given QE). Furthermore, loading curves for both QDs and phosphors were established from another set of test devices such that increasing the loading of a given downconverter does not linearly translate to the photons emitted but rather follows the loading curve previously determined. In this regard, all modeled spectra represent real devices that could be made given the existence of the proper QD emission wavelengths and FWHM values. This is an important distinction between this work and previous models [
A total of
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Figure 6.Top: Several modeled spectra are shown. Red curve:
Figure 7.LER versus FWHM results of filtered data set from modeling based on 4000 K device. The parameters and ranges of the model are found in Table
Significantly, high LER values are not achievable by virtue of narrow QD emission linewidth alone. All the modeling parameters determine the spectral shape, including QD wavelength and QE. Since not all solutions for a given LER are unique, different combinations of parameters can lead to the same LER value. Interestingly, in some cases, high LER values can be achieved by relatively low QE values. Of course, the overall efficiency of a device will be higher with higher QE values. In a related manner, highly tunable emission wavelength is the other key characteristic that allows for simultaneously reaching high LER while also meeting strict color metrics. As higher LER is demanded, by necessity, the QD wavelength must also blueshift. This represents a problem for some narrow-band phosphors that are not readily tunable such as potassium fluorosilicates, whereas this is not an issue for QDs as they are highly tunable. As seen in Fig.
Figure 8.LER versus QD peak wavelength from filtered data set from modeling based on 3000 K device. The parameters and ranges of the model are found in Table
5. DISPLAY
It is well known that, to achieve improved color metrics in lighting as well as increased gamut in display technologies, it is highly desirable to obtain a downconverter having a narrow emission linewidth [
While current LED backlight QD-based displays have tuned emission peak wavelengths for an optimal color, further increasing the Rec. 2020 coverage will come from reduced FWHM of the emission. An example of a QD converted LED for back light unit (BLU) applications is seen in Fig.
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Figure 9.Top: BLU spectrum comprised of green and red Cd-based QDs. While this spectra is representative of the FWHM values, further color tuning of the peak emission can result in much better gamut coverage. The CF72 color filters are also shown. Bottom: Modeling results showing the impact of FWHM on Rec. 2020 coverage as calculated in CIE 1931 color space. This plot includes all wavelength and loading combinations, but has been filtered such that the maximum achievable gamut for any FWHM point is layered on top. The color bar indicates the fraction of Rec. 2020 coverage. A black datum representing literature reports for InP QDs has been included for comparison.
After filtering all results, the fractional gamut coverage as a function of QD FWHM is plotted in Fig.
Figure 10.Modeling results for Rec. 2020 coverage. The Rec. 2020 gamut is defined by the black dashed line. The D65 white point and Planckian locus are identified as well. The gamut attainable via use of Cd-based QDs is specified by the purple triangle while that of a leading InP QD system is shown as an orange triangle. As is conventionally done, these are measured/calculated at room temperature. The Cd-based QD has coverage of 80.8% Rec. 2020, while the InP-based QD has coverage of 66.7%.
While the QD literature often cites emission linewidths at room temperature, it is important to know the FWHM at operating temperatures for displays. As mentioned, the Cd-based QDs presented here have wavelength and FWHM temperature dependencies that are well fit by a linear model for temperatures starting at room temperature and extending to LED operating temperatures up to 150 K. The linear temperature shift coefficients for CdSe QDs are 0.125 nm/K for wavelength shifting and 0.055 nm/K for linewidth broadening. Inasmuch as this is a property of semiconductors and that exciton recombination happens within the CdSe core, these numbers hold for a variety of shell permutations including both thick and thin shells. In a similar fashion, the InP literature was used to extract linear fit coefficients [
6. CONCLUSIONS
This new QD technology has allowed for the first commercial implementation of on-chip QD downconverters as a direct phosphor replacement. In collaboration with Lumileds, an acknowledged LED pioneer, QD materials have been shown to meet the requirements for commercial realization. Based on single-particle measurements taken on both production and experimental QD batches, the lower limit in emission linewidth for Cd-based QDs is estimated to be 20 nm using current synthesis paradigms. Achieving this linewidth on-chip with a tunable wavelength represents a significant improvement to the maximum achievable efficiency for solid-state lighting products. Furthermore, this narrow-emission linewidth coupled with high tunability allows for greatly improved color metrics while maintaining high LER values.
Acknowledgment
Acknowledgment. Thanks to the entire team at Pacific Light Technologies, the many QD synthesis experts and test experts who made this work possible by providing high-quality materials, data, and support. Also, thanks to the R&D and Product Development teams at Lumileds that have supported this collaboration by providing LEDs, expertise, and feedback as well as independent test verification of QD samples.
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Benjamin D. Mangum, Tiemo S. Landes, Brian R. Theobald, Juanita N. Kurtin, "Exploring the bounds of narrow-band quantum dot downconverted LEDs," Photonics Res. 5, A13 (2017)
Special Issue: RECENT DEVELOPMENTS IN LIGHT-EMITTING DIODE TECHNOLOGY AND APPLICATIONS
Received: Nov. 17, 2016
Accepted: Jan. 25, 2017
Published Online: Sep. 26, 2018
The Author Email: Juanita N. Kurtin (juanita.kurtin@pacificlighttech.com)