2008 LCD-BLU Report

TABLE OF CONTENTS
1 Introduction 11
    1.1.     Goals 11
    1.2.     Scope 11
    1.3.     Methodology 11
    1.4.     Executive Summary 12
2 Market Summary 18
    2.1.     Market Opportunity 18
3 Backlight Technical Review 25
    3.1.     General Requirements 25
    3.2.     BLU Classification 26
    3.3.     Direct-view BLU 27
    3.4.     Edge-light BLU 27
    3.5.     Overview of Backlight Technical Issues 28
    3.6.     BLU Design Requirements 35
    3.7.     LCD-TV BL Design Considerations 37
    3.8.     Monitor BL Design Considerations 44
    3.9.     Notebook Display BL Design Considerations 46
4 Backlight Materials and Performance Impacts 48
    4.1.     LCD Panel Industry Structure 48
        4.1.1.         LCD Panel Manufacturers 49
    4.2.     Adaptive or Controllable Backlights 51
        4.2.1.         General Considerations 51
        4.2.2.         Adaptive Dimming 52
        4.2.3.         High Dynamic Range Displays 53
        4.2.4.         Color Sequential Systems 54
        4.2.5.         Blinking Backlight for Contrast Improvement 56
        4.2.6.         Scanning Backlights for Motion Artifact Reduction 57
    4.3.     Light Sources 58
        4.3.1.         Overview/Technical Issues 58
        4.3.2.         Cold Cathode Fluorescent Lamp (CCFL) 59
        4.3.3.         External Electrode Fluorescent Lamp (EEFL) 66
        4.3.4.         Hot cathode fluorescent lamps (HCFL) 68
        4.3.5.         Flat fluorescent lamps 70
        4.3.6.         Light Emitting Diodes (LED) 77
        4.3.7.         Carbon Nanotube Lamps 95
        4.3.8.         Organic Light Emitting Diode (OLED) Backlights 96
    4.4.     Optical Films 97
        4.4.1.         Diffuser Films and Plates 99
        4.4.2.         Brightness Enhancement Films 102
        4.4.3.         Pre-polarizing Films 106
        4.4.4.         Optical Film Manufacturers 108
        4.4.5.         Reflective Films 110
        4.4.6.         Optical Film Technology Roadmaps 113
    4.5.     Light Guide Plate (Edge-lit BLs) 115
        4.5.1.         Design Considerations & Alternatives 115
        4.5.2.         Light Guide Configurations 116
        4.5.3.         Light Guide Technology Roadmaps 120
    4.6.     Backlight Electronics 121
        4.6.1.         CCFL Inverters 121
        4.6.2.         LED Drivers 123
    4.7.     BLU Manufacturers 123
5 BOM & Thru-Put Analysis 127
    5.1.     Analysis Assumptions Including: Key Technical & Supply Chain Issues 127
    5.2.     BLU Cost Models 129
        5.2.1.         Cost Model Overview 129
        5.2.2.         LCD-TV BLU Cost Model & Throughput Model 131
        5.2.3.         LCD Monitor BLU Cost Model & Throughput Model 132
        5.2.4.         Notebook LCD BLU Cost Model & Throughput Model 134
6 BLU Technology Penetration Analyses 136
    6.1.     Baseline Demand Forecast 136
    6.2.     Economic Factors 137
        6.2.1.         Why Adjust the Baseline Demand Forecast? 137
        6.2.2.         Negative Economic Indicators 137
        6.2.3.         Positive Economic Indicators 142
        6.2.4.         Is the US in a Recession? 143
        6.2.5.         When Will the Economy Recover? 143
    6.3.     Rating and Ranking of BLU Alternatives 143
    6.4.     Notebooks 149
        6.4.1.         Baseline Notebook Demand Forecast Size 149
        6.4.2.         Adjusted Notebook Demand Forecast 151
        6.4.3.         Notebook BLU Technology Penetration Forecasts 152
    6.5.     Monitors 154
        6.5.1.         Baseline Monitor Forecast 154
        6.5.2.         Adjusted Monitor Demand Forecast 156
        6.5.3.         Monitor BLU Technology Penetration Forecasts 156
    6.6.     LCD-TVs 160
        6.6.1.         Baseline LCD-TV Forecast 160
        6.6.2.         Adjusted LCD-TV Forecast 162
        6.6.3.         TV BLU Technology Penetration Forecasts 164
7 Backlight Unit Opportunity Analyses 175
    7.1.     LCD-TV Backlights 175
      Electronics 175
      Optical Films 175
      Light Sources 175
      Mechanical 176
      Supply Chain 176
    7.2.     LCD Desktop Monitor Backlights 176
    7.3.     Notebook PC Backlights 176
    7.4.     Conclusions 177
8 Appendix A - LCD BLU Cost Breakdown Summary 178
9 Appendix B - BLU Throughput Analysis 182
    9.1.     Throughput Model Analysis - Overview 182
10 Appendix C - Color Gamut Metrics for LCD Displays 185
11 Appendix D - Acronyms Used in Report 191
Table of Figures
Figure 2-1: World Wide LCD Panel Shipments and Forecast (Source: Displaybank) 18
Figure 2-2: LCD Worldwide Shipments, Forecast and Growth (Source: Displaybank) 19
Figure 2-3: LCD Monitor Price Trends for 12 Months Preceding March 2008 (Source: Displaybank) 22
Figure 2-4: LCD-TV Price Trends for 12 Months Preceding March 2008 (Source: Displaybank) 22
Figure 2-5: Notebook LCD Panel Price Trends for 12 Months Preceding April 2008 (Source: Displaybank) 23
Figure 2-6: Monitor LCD Panel Price Trends for 12 Months Preceding April 2008 (Source: Displaybank) 23
Figure 2-7: LCD TV Panel Price Trends for 12 Months Preceding April 2008 (Source: Displaybank) 24
Figure 3-1 Typical LCD Module Construction 26
Figure 3-2 Comparison of Direct-View (L) and Edge-Light (R) BLU (Mechanical Housings Omitted for Clarity) 27
Figure 3-3 Typical Lamp/Reflector Assembly for Edge-Lit BLU 28
Figure 3-4 Edge-Light BL with Wedge-Type Light Guide 28
Figure 3-5 Example of Dynamic Contrast Expansion Using BL Area Dimming 31
Figure 3-6 Example of Motion Blur Reduction Using BL Flashing 32
Figure 3-7 CIE Diagram Showing Typical and Expanded Color Gamuts 33
Figure 3-8: Active Matrix OLED Display 34
Figure 3-9 Relative Importance of Various Performance Factors for LCD-TV, Monitor & Notebook Displays 36
Figure 3-10 LCD-TV BLU Assembly and Exploded View (R) Showing Typical Film Stack. 38
Figure 3-11 Color Gamut Plot of Multi-Primary LCD With and Without WCG CCFL; Spectral Comparison of Normal and WCG (Custom for MPC LCD)9 39
Figure 3-12 Comparison of Motion Blur Reduction Methods (Courtesy of Samsung Corning) 41
Figure 3-13 Lamp Reduction Uniformity Explanation: Original Lamps and Film Stack (L), Reduced Lamp Count and Original Film Stack (R), Reduced Lamp Count and Improved Film Stack (C) Showing Higher Luminance with Original Uniformity 44
Figure 3-14: Monitor BLU Assembly (L) and Light Guide Insertion (R) 46
Figure 3-15: Monitor BLU View of Lamp Holder (L) Showing Dual-Lamp Configuration, and Exploded View (R) Showing Typical Film Stack 46
Figure 4-1 LCD Module and Product Industry Structure 48
Figure 4-2 CEYX Technology BLU Logical Design 52
Figure 4-3: High Dynamic Range Display from Dolby: LED Array with LCD Panel (L) and High Dynamic Range LCD Monitor (R) 54
Figure 4-4: Color Sequential LCD 55
Figure 4-5: Contrast Improvement with a Blinking Backlight 56
Figure 4-6: Motion Artifact Reduction with a Scanning Backlight: HCFL Illumination (L) and Ideal Timing Diagram for a Scanning Backlight (R) 57
Figure 4-7 Structure of Cold Cathode Fluorescent Lamp 60
Figure 4-8 Operation Principle of Fluorescent Lamp 60
Figure 4-9: CCFL Electrode Material Performance (Data Courtesy of Kumho Electric) 63
Figure 4-10 Harison Toshiba Life Test Data for Over-Coated Phosphor CCFL 64
Figure 4-11 Comparison of UV Emission in CCFLs with (L) and Without (R) UV Treatment 66
Figure 4-12 External Electrode Fluorescent Lamp Structures 66
Figure 4-13 Comparison of Lumen Maintenance (L) and Chromaticity Shift (R) for HCFL and CCFL Lamps (from Wellypower) 69
Figure 4-14: FFL BLU Structure Compared to CCFL BLU 70
Figure 4-15: Luminance Output Over Operating Temperature for Hg-CCFL and Hg-Free FFL 71
Figure 4-16 Flat Fluorescent Lamp with Tubular Structure (Note Photo at Left is Contrast Enhanced to Show Tubular Structure) 72
Figure 4-17 Schematic of Two FFL Structures: Basic Structure (L) and Osram Planon (R) Showing Coplanar Electrode Configuration. 73
Figure 4-18 FFL Electrode Patterns and Discharge Characteristics of Several Manufacturers 74
Figure 4-19 Efficiency Projections for Hg Free FFL (from Samsung Corning) 75
Figure 4-20 Example of Contrast Extension with Local Area Dimming (A) and Overdrive (B) Using Samsung Corning "Active Brightness Control" 75
Figure 4-21 Cost Projections for Hg Free FFL (from Samsung Corning) 76
Figure 4-22 Comparison of LED Efficiency with Junction Temperature (From Lumileds) 82
Figure 4-23 Alternate Configurations of White LEDs: BLUE + YEL Phosphor (L), BLUE + RED Enhanced Phosphor (C), RGB Die (R) 83
Figure 4-24 Comparison of Manufacturers Color Bins for White LEDs 84
Figure 4-25 TV BLU Using Early Lumileds High-Flux LED Design 85
Figure 4-26 Alternate LED Configurations for Direct View LED BLUs 86
Figure 4-27 Luminus Devices BLU Using PhlatLight LED Module 86
Figure 4-28 High-Power White LEDs - Lumileds Rebel (L) [70L @ 350mA], Osram Golden Dragon (R) [45L @ 350mA] in RGGB Quad Layout and Nichia NS6W083T [60L @ 30mA] 88
Figure 4-29 Mid-Power White LEDs (PLCC-6) - Osram LWG6SP (L) [18L @ 140mA] and Avago ASMT-QWB2-Nxxxx [17L @ 150mA] 88
Figure 4-30 Edge-Lit LED Monitor BLU (L) and ERG LED Rail (R) 89
Figure 4-31 RGB SMD LEDs: Kingbright (L) and Osram Opto (R) 90
Figure 4-32 Notebook LCD LED BLU Implementation and Inlet Optic (L) from GLT 91
Figure 4-33 Example of Prism Light Guide Implementation (from Enplas) 91
Figure 4-34 Depiction of LED Color and Luminance Variation Impact on Notebook Display Uniformity 92
Figure 4-35 Toyoda Gosei Co. (White: E1S63-YW1T7-06) SEOUL Semiconductor (White: KWTS907) and Nichia (RGB: NSSM038AT) 93
Figure 4-36 CNT Technology from Iljin Nanotech (L) and Samsung SDI (R) 96
Figure 4-37 Typical Film Configurations for TV, Monitor and Notebook BLUs 98
Figure 4-38 Optical Film Trends for TV BLUs 98
Figure 4-39 Diffuser Products (top) - Sejin T.S. Co.; Haze and Transmission Characteristics (bottom) - SKC, Inc. both of Korea 100
Figure 4-40 Coated Diffuser Film Depiction (L) and Photomicrograph of Coated Diffuser (C) and Micro-Structured Surface Diffuser - GE Illuminex (R) 101
Figure 4-41 Volumetric Diffuser (GE Illuminex) 102
Figure 4-42 Directional Diffuser Intensity Distribution 102
Figure 4-43 BEF Operational Principal 103
Figure 4-44 Examples of Prism Film Luminance Gains: Vertical & Horizontal vs. Viewing Angle for Single Prism Film (L), and On-Axis Gain for Single- and Crossed-BEF-III (R) 104
Figure 4-45: Photomicrographs of Surface Relief Diffusers: Circular (L) from Reflexite, Elliptical (C) from Luminit, and Standard Products Table from Wavefront (R). 105
Figure 4-46: Structure of Kodak "Brightness Enhancement Article" from US 7,160,017 106
Figure 4-47: Operational Principle of Reflective Pre-Polarizer (DBEF) 107
Figure 4-48: Performance Example for Notebook LCD Module with DBEF (L) and Without 107
Figure 4-49 Structure of Gore DRP (from US 5,892,621) 111
Figure 4-50 Furukawa MC-PET Structure and Performance 111
Figure 4-51 DuPont Optilon Performance Characteristics 112
Figure 4-52 Optical Film Technology Roadmap - MNTech (Korea) 113
Figure 4-53 New Version Prism Films: Efun (L), Gamma Optical (C), Shinwha (R) 114
Figure 4-54: Micro-Lens Patterned Multi-Functional Film (Shinwha) 115
Figure 4-55: Shinwha Intertek Multi-Functional Prism Film (L), MNTech (R) 115
Figure 4-56 Edge-Light BL with Wedge-Type Light Guide 116
Figure 4-57 Typical Flat-LGP BLU Structure and Prism Sheet Geometry 117
Figure 4-58: LGP Texture Development Roadmap (from LITS, Inc., Korea) 118
Figure 4-59: LGP Gradient Texture Example from US 5,093,765 (L) and Product Examples (R) 118
Figure 4-60 LGP Texture Pattern Examples (from Radiant Opto-Electronics Corp., Taiwan) 119
Figure 4-61 Prism-Type LGP BLU Structure and Reverse Prism Sheet Geometry 119
Figure 4-62 Comparison of Conventional to Prism-Type LGP BLUs 120
Figure 4-63 Light Guide Plate with Inlet Features for Broadly Spaced LEDs (from US 6,797,095 - Samsung) 121
Figure 4-64 Single Lamp (L) and Multi-Lamp CCFL Inverter/Controllers (from US 6,459,216) 121
Figure 4-65 Multi-Lamp CCFL Inverter/Controllers from US 7,042,171 (L) 122
Figure 4-66 Standard 16 Output CCFL Inverter (L) and "Auto-Balance Inverter (R) Showing Four-Fold Reduction in Transformers (courtesy of Kumho Electric) 122
Figure 4-67 Color Sensing and Control Circuits: Lumileds Block Diagram and Avago Controller 123
Figure 6-1: Displaybank's Worldwide LCD Panel Demand Forecast by Category 136
Figure 6-2: Baseline Notebook LCD Panel Demand Forecast by Size 150
Figure 6-3: Comparison of LED Penetration Forecasts 152
Figure 6-4: LCD Monitor Panel Demand Forecast by Size 156
Figure 6-5: LED BLU Forecast by Monitor Size and Year 159
Figure 6-6: LCD-TV Panel Demand Forecast by Size 161
Figure 6-7: Historical Look at LED BLU Product Offerings 165
Figure 6-8: TV BLU Edge-Light Size Market Penetration 168
Figure 10-1: Chromaticity Diagram, 1931 CIE. 186
Figure 10-2: Video Display Color Gamut Standards on CIE 1931 Diagram. 187
Figure 10-3: Pointer Color Gamut Compared to NTSC on the CIE 1931 Diagram. 189
Table of Tables
Table 1-1 Companies Interviewed for 2008 BLU Report 12
Table 1-2 Relative BLU Performance for Various Light Source Technologies 14
Table 1-3 Projected LED BLU Penetration into Notebook and TV Products 15
Table 1-4 Key Analysis Positions for BLU Light Source Technologies 17
Table 3-1 Technical Issues of Interest to LCD-TV, Monitor and Notebook Panel Manufacturers 29
Table 3-2: Summary of Key requirements for TV, Notebook and Monitor Products and BLU 37
Table 4-1: Worldwide LCD Panel Manufacturers 50
Table 4-2: Top CCFL Lamp Manufacturers (90% of Worldwide Shipments) 62
Table 4-3: Sanken Electric Typical Lamp Product Data 64
Table 4-4 Mechanisms of Hg Consumption in CCFL and Proposed Improvement Actions (from Wellypower, Inc.) 65
Table 4-5 Manufacturers of EEFL for Large Screen Applications 68
Table 4-6 NuLight FFL Product Availability 77
Table 4-7 Recent LED Backlight Penetration Forecast 78
Table 4-8 Current LED Backlit Commercial Products 79
Table 4-9 LED Technical Benefits and Challenges Summary 80
Table 4-10 Comparison of LED Benefits, Issues and BL Options by Product Category 81
Table 4-11 Monitor LED Backlight Performance Estimate 89
Table 4-12 NB LED Quantities by Size 93
Table 4-13 Leading LED Suppliers for LCD BLU Applications 94
Table 4-14 Optical Film Manufacturers Worldwide 109
Table 4-15: Reflector Film Manufacturers 112
Table 4-16 LCD BLU Manufacturers with Notebook, Monitor and/or TV Capability 126
Table 5-1 Key Analysis Positions for BLU Light Source Technologies 128
Table 5-2 Key Analysis Positions for BLU Components 129
Table 5-3: CCFL BLU Cost Model by Application, Size and Resolution 130
Table 5-4: LCD TV BLU Cost Comparison for Selected Module Configuration (High-Flux RGB-LED is Edge-Lit) 132
Table 5-5: LCD TV BLU Throughput Analysis - CCFL, Enhanced W-LED and High Flux RGB LED (Please see Appendix B for a detailed explanation of Throughput) 132
Table 5-6: LCD Monitor BLU Cost Comparison for Selected Module Configurations 133
Table 5-7 LCD Monitor LED BLU Throughput Analysis - CCFL and White LED (Please see Appendix B for a detailed explanation of Throughput) 134
Table 5-8 Notebook BLU Cost Comparison for Selected Module Configurations 135
Table 5-9 Notebook LED BLU Throughput Analysis - CCFL and White LED (Please see Appendix B for a detailed explanation of Throughput) 135
Table 6-1: Explanation of BLU Performance Criteria 146
Table 6-2:: Summary of Relative BLU Performance 146
Table 6-3: Performance Weighting by Application 147
Table 6-4: Notebook Weighted Relative BLU Performance 148
Table 6-5: Monitor Weighted Relative BLU Performance 148
Table 6-6: LCD TV Weighted Relative BLU Performance 149
Table 6-7: Baseline Notebook LCD Panel Demand History and Forecast by Size Range 150
Table 6-8: Notebook Panel Demand Adjustment Matrix 151
Table 6-9: Notebook Panel Adjusted Demand Forecast 151
Table 6-10: Forecast LED BLU Product Penetration in Notebook LCD Panels 153
Table 6-11: LCD Monitor Panel Demand History and Forecast by Size Range 155
Table 6-12: Adjustment Matrix for Monitor Demand Forecast 156
Table 6-13: Adjusted Monitor Demand Forecast 156
Table 6-14: Forecast LED BLU Product Penetration in Desktop Monitor LCD Panels 158
Table 6-15: Baseline LCD-TV Panel Demand 161
Table 6-16: Baseline LCD TV Demand Forecast by % Screen Size 162
Table 6-17: LCD TV Demand Adjustment Matrix 164
Table 6-18: Adjusted LCD TV Demand Forecast 164
Table 6-19: Key Technical Assumptions in TV BLU Analysis 167
Table 6-20: TV CCFL BLU Market Penetration Forecasts (includes HCFL & EEFL) 169
Table 6-21: TV LED BLU Market Penetration Forecasts 170
Table 6-22: 2006 BLU Penetration Results 171
Table 6-23: 2007 BLU Penetration Results 171
Table 6-24: 2008 BLU Penetration Forecast 172
Table 6-25: 2009 BLU Penetration Forecast 172
Table 6-26: 2010 BLU Penetration Forecast 173
Table 6-27: 2011 BLU Penetration Forecast 173
Table 6-28: 2012 BLU Penetration Forecast 174
Table 8-1 Notebook BLU Cost Breakdown for Selected Configurations 178
Table 8-2 BLU Configurations for Notebook 178
Table 8-3 Monitor BLU Cost Breakdown for Selected Configurations 179
Table 8-4 BLU Configurations for Monitor 179
Table 8-5 LCD TV BLU Cost Breakdown for Selected Configurations 179
Table 8-6 BLU Configurations for LCD TV 180
Table 8-7 Example Cost Analysis and Forward-looking Projections for LED Notebook BLU 180
Table 9-1 Units and Measures 182
Table 9-2 Example of BLU Calculations for 42" 1080p LCD TV Module 184
Table 10-1 Color Coordinates (CIE 1931) for Key Video Color Gamut Standards. 188
 

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