LED backlight module cost reduction into design direction

The backlight is one of the important components of TFT-LCD (Thin Film Transistor Liquid Crystal Display). Due to its low energy consumption, high image quality, long life and environmental protection, it has become the focus of attention in the industry. Since Sony introduced the first LCD TV with LED as the backlight in 2004, the technology and performance of LED devices have been continuously improved. The research and development of various LED backlight technologies at home and abroad have also been carried out in an all-round way. At present, small and medium-sized panels applied to mobile intelligent terminals have basically adopted LEDs as backlight sources. With the problems of light efficiency and price being alleviated and solved, a large number of LED light sources have been gradually installed into large-sized backlight modules. Its mainstream status has tended to be stable. With the large number of LEDs being used, more and more technologies such as dynamic backlight control technology, ultra-thin technology and heat dissipation technology are applied to the backlight module, which makes the backlight module industry gradually change the characteristics of labor-intensive in the past. With more and more technology added value, the role in the industry chain is becoming more and more obvious.
The picture shows the LED backlight module
The picture shows the LED backlight module
LED backlight module determines the success or failure of the panel
The backlight module basically determines the power consumption of the TV, the cost of the TFT-LCD panel, and the user's experience with the terminal display.
The backlight module is one of the key components of the LCD panel. Its importance is mainly reflected in three aspects: First, the backlight module basically determines the power consumption of the TV. Since the TFT-LCD panel changes the alignment direction of liquid crystal molecules by an electric field, its power consumption is extremely low. The power consumption of TFT-LCD is mainly composed of TFT circuit, driving circuit and backlight module. The backlight module consumes 80% of the power consumption of the TFT-LCD, while the power consumption of the TFT-LCD panel accounts for 80% of the LCD TV. Therefore, it can be seen that the backlight module is integrated in the LCD TV. The highest share of consumption.
Second, the backlight module basically determines the cost of the TFT-LCD panel. The backlight module consists of three parts: LED light source, light guide plate and optical film, accounting for 72% of the cost of the entire backlight module. The light source is the light tube. The function of the light guide plate is to atomize the line light source into a surface light source. The main function of the optical film is to condense light and improve brightness. Among them, the optical film is the most expensive, accounting for 44% of the cost of the backlight module, the light guide plate accounts for 16%, the lamp tube accounts for 12%, and other such as the lampshade and the outer frame account for 28%. More than 70% of the cost of the TFT-LCD panel module is raw materials, and the backlight module accounts for 20% to 30% of the cost of the panel module. Therefore, the backlight module occupies the highest share of the cost structure of the TFT-LCD.
Third, the advantages and disadvantages of the backlight module basically determine the user's experience of the terminal display effect. The demand for display effects has gradually increased, and the demand for wide viewing angle, low power consumption, faster response speed, and richer color expression has become a key factor in determining the quality of backlight modules.
Low cost into an important design direction
The penetration of LED backlights tends to be saturated in the short term. In order to stimulate the penetration of products, many manufacturers have developed their designs in a low-cost direction.
The analysis of the development trend of LED backlight modules in the future can be summarized as follows: First, LED backlights will officially become the mainstream of the backlight market. LED backlight is a powerful substitute for CCFL. With the maturity of LED technology and the continuous decline of cost, the application rate of LED backlight module in LCD has increased year by year. In 2009, the global penetration rate of LED-backlit LCD TVs was less than 1%. According to market research firm IDC data, in 2012, the global LED backlight TV shipment penetration rate has reached 73%, and the shipment penetration rate is expected to reach 86% in 2013. These data show that the LED backlight module has become the standard for LCD TV configuration, and the trend of becoming the mainstream in the market is unstoppable.
Second, low-cost LED backlights will further become the focus of the market. LED backlights have been widely used in 1-inch to 70-inch liquid crystal displays, and the price of LED chips has been one of the important factors hindering the further popularization of LED backlights. As more manufacturers participate in the development of LED backlight technology and the cost of LED chips brought about by MOCVD localization, the production cost of LED backlight modules will be reduced to some extent. At present, in order to stimulate the improvement of the penetration rate of LED backlight products, many manufacturers have developed the design toward low cost.
Third, the side-lit dynamic backlight and low-power technology will be more popular in the industry. Nowadays, large-size TV products in mass production generally use direct-type CCFL as a light source. Not only the power consumption is relatively large, but the technological development is also close to the theoretical limit. The side-illuminated LED large-size backlight technology combines ultra-thin and beautiful appearance, and is integrated with regional control technology, which can greatly reduce the power consumption of the backlight.
Fourth, the panel and the whole machine manufacturer are expected to extend the industrial chain to the backlight module. There are already signs that as panel makers become larger, they want to invest in or acquire backlight module manufacturers to capture capacity. The lower TV backlight module is often the first choice for panel manufacturers. Overall, TV manufacturers and LCD panel factories are the major demand for backlights. As the cost of LED chips continues to decline, panel and machine manufacturers will be able to extend the industry chain to the backlight module. For the whole machine enterprise, due to the increasingly fierce competition in the liquid crystal display industry in recent years, enterprises can only effectively solve the problems of competing with major international manufacturers for key raw materials, reducing costs, and achieving product differentiation. Therefore, the TV factory and the panel factory set up the LCD module factory, or the module factory for the TV factory and the panel factory to produce, and finally form an industrial cluster, which will become the mainstream business model of the LED backlight module industry in the future.
Fifth, the penetration rate of LED backlights tends to be saturated in the short term. From a global perspective, the LED backlight penetration rate of major electronic products has reached a high level, and LED backlight demand will enter a mature stage after 2013. In the future, as the capacity expansion of mobile intelligent terminal products tends to be rational, the actual demand for small and medium-sized panels will also become saturated. Therefore, the high growth stage of LED backlights is about to pass. It is expected that the main growth driver of LED backlights in the future will be the growth of the backlight market brought by the high pixels of electronic products. The unfavorable factor is the advancement of process technology, especially the improvement of chip light efficiency, which will lead to a reduction in the actual demand for LED chips.
Innovative technology can win the living space
Under the huge pressure from the upstream and downstream sides, the profit margin of backlight module products is getting smaller and smaller, and the operation and survival of some manufacturers, especially second-tier manufacturers, are getting more and more difficult.
At present, the development of the LED backlight industry is mainly reflected in the balance between cost and profit. Because in the increasingly developed and mature TFT-LCD industry chain, the labor-intensive features of the backlight industry and relatively low entry barriers have led to the current fierce competition in the backlight industry. On the one hand, upstream key materials such as optical films are still in the hands of a few manufacturers, the price of materials is difficult to decline, resulting in high product costs; on the other hand, it faces the pressure of downstream customers to continuously demand price reduction. Under the huge pressure from the upstream and downstream sides, the profit margin of backlight module products is getting smaller and smaller, and the operation and survival of some manufacturers, especially second-tier manufacturers, are getting more and more difficult. Affected by the cyclical fluctuations in the TFT-LCD industry, when the LCD industry enters a sluggish cycle, the backlight module industry, which is winning by quantity, will encounter greater operational pressure.
China's mainland region has a broad market space for liquid crystal display, providing an unprecedented market opportunity for the development of the backlight industry. However, compared with backlight manufacturers in Japan, South Korea and Taiwan, which have strong technical strength and industrial scale, there is still a certain gap between the technical strength and production scale of the backlight industry in mainland China. In order to solve these problems, the following suggestions are made:
First, we must upgrade the key core technologies of small and medium-sized backlights. Should study the appropriate optical sawtooth and mesh point matching; master and apply the iron frame plastic frame integration technology, applied to ultra-thin mobile phone products.
Second, we must strengthen the development of ultra-thin LED backlights for liquid crystal displays and notebook computers. By reducing the thickness of the LGP, reducing the number of layers used by the FILM, reducing the number of LEDs used, and achieving ultra-thin and low power consumption, the products are competitively priced.
Third, we must strengthen the development of ultra-thin light guide plates. Through optical design and mold forming, the optimal mold structure and molding parameters can be found to achieve stable mass production of ultra-thin light guide plates.
Fourth, we must strengthen the research on the automatic assembly line of backlights. Strengthen the research on backlight automatic assembly equipment and technology, and expand the scale of backlight production automation.
Fifth, we must strengthen the research on key raw materials upstream of the backlight and improve the matching rate of localization. Facing the upstream of the industry, we will study the process technologies of key materials such as light guide plates, optical films and LEDs, implement a number of upstream supply chain construction projects, and improve the localization matching rate of key raw materials for backlights.
Sixth to strengthen the backlight frontier and alternative technology research. Pay close attention to the development of the backlight industry, focus on strengthening the frontier of backlights or alternative technologies, such as OLED backlights, and make technical reserves ahead of the future development of the industry.
Seventh, it is necessary to strengthen the independent intellectual property rights of domestic LED backlight technology and avoid patent risks. We should pay attention to the following two points: First, strengthen cooperation between industry, universities and research institutes, promote the transfer of innovation results of scientific research institutions to enterprises, and effectively avoid intellectual property risks; second, we must take the road of technological growth of Japanese and Korean companies and conduct core patents for competitors. Improvement, and then apply for improved patents, practice has proved that this is an effective way to circumvent patent barriers.

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