Made in America – Sapphire for the High Growth LED Market

While Google made a splash recently about making the Nexus Q media player in the US, companies all over the US are making key contributions of the economy by manufacturing in America.  One of the key building blocks for LEDs is sapphire.  Much like silicon is used for computer chips, sapphire is the foundation for an LED chip.  Illinois-based Rubicon Technology is one of the world’s leading producers of sapphire ingots, blanks, polished substrates and windows. With more than 80% of the world’s LEDs based on sapphire, Rubicon makes a very important contribution to the market right here in the US.

Rubicon grows large sapphire crystals in sapphire furnaces in its Franklin Park, Batavia and Bensenville, Illinois-crystal growth facilities.  The company makes very large sapphire crystals – bulk crystal ranging in size from 30 kg to 85 kg to 200 kg – that are cored and shipped to a Rubicon finishing facility in Malaysia or to directly to finishing customers throughout Asia to make sapphire wafers that and then made into millions of little LED chips.  These LED chips are found in everything from smartphones, laptops and tablets, HDTVs, big ad displays, street lights, commercial lighting and even new LED light bulbs.

Why manufacture the sapphire crystals in the US?  According to Rubicon, the crystal growth process is a high precision process that uses energy that must be kept constant. Any deviation in the power during the crystal growth process can lead to imperfections in a crystal rendering that crystal unusable.

Based on a decade of Rubicon company experience and decades of semiconductor expertise, Rubicon has custom-built next-generation crystal growth furnaces for their US plants. Rubicon’s innovations have resulted in industry-leading large-diameter sapphire wafers – six inches or more in size versus the commonly made two, three and four inch wafers – that help bring LED chip manufacturers cost efficiencies they can’t achieve with smaller wafers.  To date, Rubicon has shipped 230,000 large diameter wafers.

“No other country in the world has reliable, low cost utilities like the US,” said William Weissman, CFO for Rubicon.  “We specifically have designed our crystal growth facilities around reliable resources for power and water.  The location in the US also allows us to protect our intellectual property inherent in our furnaces and processes in a way that cannot be maintained outside of the country.”

This entry was posted in Emerging Markets, LED, LED Chip, LED industry, manufacturing, sapphire, sapphire boule, sapphire crystal, sapphire substrate, sapphire wafer and tagged , , , , , by Beth. Bookmark the permalink.

About Beth

It seems like LEDs are in everything these days – backlighting everything from your mobile phone, Apple iPad and flat screen HDTV to traffic lights, light bulbs and even the kitchen sink. But, making LEDs is a complex process that begins with the creation of sapphire. Not the pretty blue gemstone, but large commercial crystals that can weigh as much as 400 lbs. Once these large sapphire crystals are grown into boules and cooled, they’re cut into cores, cut further into flat circular wafers, polished and then used to grow LEDs. About 85 percent of HB-LEDs (high brightness) are grown on sapphire. There’s not that much information out there about the process. This blog is meant to shed some light (excuse the pun) on sapphire, LEDs and the industry that is devoted to making our lives just a little brighter. In the months ahead, we’ll tackle some topics that will help you understand a little more about sapphire and LED industry. Here’s a sample of what we’ll cover in the coming months: • Growing sapphire • For a wafer, size matters • Quality - When sapphire wafers go bad • LED light bulbs • Market & myths • Interviews with industry shining stars • Reports from industry events • Current events in perspective Please join us each week to learn more about sapphire and the LED market. We look forward to seeing you.

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