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[Analyst Column] Encapsulation Technology, Where is it Going?

Yi Choong Hoon Yi, Chief Analysis / UBI Research

인캡사진

OLED market is heating up again. Rigid OLED market growth was temporarily stalled but with Samsung Electronics and LG Electronics’ new flexible (plastic) OLED products, Galaxy S6 Edge and G Flex 2 respectively, the smart phone market’s temperature is rising. In order to maintain the storm that iPhone brought, Apple is preparing to release smart watch equipped with LG Display’s plastic OLED. Additionally, LG Elec. is targeting the premium TV market with their 55 inch and 65 inch UHD OLED TV.

OLED panel leading company Samsung Display decided on Gen 6 line’s additional investment for flexible OLED production expansion. LG Display also decided on supplemental extension of Gen 4 line in Paju responding to the shortage of plastic OLED supply. Furthermore, JDI is joining in and expected to begin Gen 6 flexible OLED line establishment soon.

Recently announced Samsung Display’s decision to invest in large OLED line is the most encouraging news. Frontline leader in OLED display, Samsung Display mass produced 55 inch OLED panel using RGB OLED and LTPS TFT technology. However, halting the production, Samsung Display explored for technology with better business value and recently selected to produce large OLED panel using WRGB OLED technology.

OLED panel production technology can be largely separated into 3 parts: TFT, OLED, and encapsulation. Large OLED panel production technology is very difficult to obtain yield compared to small panel. Therefore, while the above 3 technologies are important in producing good panel, technology that can acquire good yield for mass production can guarantee business value. Particularly, as encapsulation is the last process, the final yield depends on the encapsulation method.

In that case, what encapsulation technology is most suitable for large area OLED panel production? As OLEDNET article published on January 12 mentions, from the technology trend perspective the answer is hybrid encapsulation technology. This technology is completed with device’s passivation film, moisture proof top plate that can cover the top, and organic material that adhere the top and passivation film. From the design trend perspective, the technology must be able to bend. Recently, the TV market is moving toward curved design, and to respond to rollable display as well the top plate has to be metal rather than glass. (Reference, 2015 OLED Encapsulation Report, UBI Research)

Hybrid encapsulation technology can be further divided into film method and dam & fill method depending on the adhesive structure between top plate and passivation film. Film method is being applied to mass production by LG Display, and dam & fill method was developed led by Sony. This method dispenses adhesive polymer liquid after organic dam installation on the panel border. This can only be used when the top plate is glass. LG Display completes the process by sealing the metal plate laminated with adhesive film to the device. A best suited technology for curved TV and rollable TV production.

The OLED panel for TV production technology decided by Samsung Display was initially known to select WRGB OLED structure similar to LG Display, but TFT and encapsulation technology have not yet been revealed. However, TFT technology is highly likely to be oxide TFT. (Reference February 27 OLEDNET article) LTPS TFT has high investment cost compared to oxide TFT and has low business value at similar performance.

What is left is encapsulation technology. For this technology also a method already commercialized by LG Display, film lamination method, is most suitable since metal plate is favorable for curved design. Metal plates is strong against external shocks and favorable for heat sink. Glass has lower heat conductivity compared to metal and requires additional protection against heat; this means that production cost can only increase. Considering design, protection against external shocks, and reduced heat sink cost, LG Display’s hybrid encapsulation technology that uses metal plate is the most ideal. Therefore, the direction that Samsung Display should also head toward is metal plate and film using method.

Although small OLED for mobile technology developed by Samsung Display became the norm, it is estimated that LG Display’s technology will become standard for large OLED panel production.

Chinese Companies’ Aggressive Chase, BOE’s Active Secondary Investment for OLED

It was revealed that public tendering began regarding BOE’s 5.5G AM-OLED project on ICB Operator, a Chinese international tendering network site.

BOE possesses Gen 5.5 AMOLED line in Ordos, and is preparing mass production using SNU’s evaporator. It is analyzed that the additional investment regarding Gen 5.5 AMOLED project has been confirmed as SNU evaporator yield has mostly settled. It is estimated that BOE’s mass production of AMOLED panel for mobile will be able to begin earnestly in the second half of the year.

BOE, OLED Project Public Tender List

BOE, OLED Project Public Tender List

<Source: ICB Operator>

Chinese panel companies aiming for mass production of AMOLED panel for mobile in 2015 are Visionox, Truly, Tianma, and EverDisplay as well as BOE. Of these, EverDisplay is known to be already supplying panel’s sample base.

The focus is now on how the active mass production of Chinese OLED panel companies will affect the OLED industry which is currently being led by Korea’s Samsung Display and LG Display.

LCD, Busy Playing Catching Up to OLED…

Following smart phone, other devices equipped with display such as tablet PC, monitor, and TV are mostly using OLED panel. In turn, LCD is attempting to replicate key points of OLED panel to catch up.
The first is LTPS TFT technology. When Samsung Display started producing AMOLED using LTPS TFT, it was overlooked by the LCD sector as it financially needed twice the amount of investment compared to a-Si TFT technology and therefore thought it to have no business value. However, as the smart phone resolution is getting higher, LCD companies are also employing LTPS TFT that has high mobility.
The second is the ultra slim thickness of OLED panel that does not have BLU. To answer the smart phone’s need for a thin body with light weight, LCD is thinning the panel by slimming the glass substrate further and further. Nowadays, even TV sector of LCD is busy trying to become thinner. In CES2015, Sony exhibited ultra slim LCD TV with thickness of approximately 4.9mm.

150225_LCD, OLED 따라 가기 정말 바쁘다~~~ <CES2015, Sony Floating Style 65” UHD LCD TV>

The third is curved design. LG Elec. and Samsung Elec. exhibited curved OLED TV using thinness of OLED panel in CES2013. With the products on the market, LCD TV also reduced thickness and began selling curved LCD TV.

150225_LCD, OLED 따라 가기 정말 바쁘다~~~1<CES2015, Hisense Curved LCD TV>

Hisense, a Chinese brand, exhibited LCD TV with curved design in CES2015. Samsung Elec. decided that the main product of 2015, SUHD LCD TV, will have curved design, as well as releasing a curved LCD monitor. However, despite reducing the thickness LCD cannot yet be applied to smart phones.

The fourth is color reproductivity rate. The existing LCD TV can only produce approximately 80% of NTSC standard, which is limited compared to 110% of OLED. LCD sector criticized OLED’s color reproduction to be excessive; however, they recently developed new technology of applying quantum dot materials onto BLU and launched the sales of LCD TV with almost 120% of NTSC. Furthermore, it is deceiving the public by calling the QD BLU LCD TV as Quantum Dot TV packaged as a non-LCD TV.

150225_LCD, OLED 따라 가기 정말 바쁘다~~~2<CES2015, TCL QD BLU LCD TV>

The fifth is contrast ratio. OLED TV’s contrast ratio is close to infinite with 1,000,000:1. Compared to this, LCD TV’s contrast ratio was 1,000:1, and unable to showcase dark scenes. Recently, HDR (high dynamic range) technology that brightens bright scenes and darkens dark scenes is strengthening its contrast ratio. Sony is striving to achieve high contrast ratio for LCD TV, similar to OLED TV, and exhibited HDR technology applied BRAVIA in CES2015.

150225_LCD, OLED 따라 가기 정말 바쁘다~~~3<CES2015, Sony HDR applied LCD TV>

Many key points of OLED such as previously mentioned thickness, contrast ratio, and curvature ratio still need to be improved by LCD panel, and diverse attempts are continually being made to catch up to OLED panel that is entering the market with great strength. However, LCD cannot yet even attempt to match OLED on high speed response time that is needed for programs with fast action such as sports.

OLED holds diversity in color definition and design, and even if LCD keeps on reaching for these characteristics, LCD will remain LCD and will not be able to overtake OLED.

Samsung Display, 2015 to be the year of flexible OLED!

The A3 line of Samsung Display is moving silently. Reigning as the best in the mobile AMOLED industry, Samsung Display has been preparing the flexible AMOLED as its next prey for a long time.

Samsung Display provided the flexible AMOLED for Galaxy Note Edge following Gear Fit and Galaxy Round, and the next model to be released from the second quarter of this year is the dual-edge curved panel.

The target is Galaxy S6.

To continue the success of Galaxy Note Edge, Samsung Electronics is to take the flexible AMOLED in full scale on its flagship Galaxy S series. This model is expected to be unveiled at MWC2015 and it will hit the shelves from April in two models as equipped with the existing rigid AMOLED and flexible AMOLED.

Considering the capacities and yielding rates of Samsung Display’s A2 and A3, it is estimated that about 3~4 million of the 5-inch flexible AMOLED will be produced.

150208_삼성디스플레이, 2015년은 flexible OLED 시대로 확 바꾼다!

<Expected design of Galaxy S6 dual-edge>

[Analyst Column] The last station of TV is the contrast ratio as seen at CES2015

Began from a CRT, also called brown-tube, the TV market went through a LCD TV, a PDP, and a LED and finally reached at an OLED TV. The TV market with the history of almost 80 years now narrowed down to the war between a LCD TV and an OLED TV.

Theoretically speaking, it is genetically difficult for both a LCD TV and an OLED TV to become a better TV than a brown-tube as LCD realizes gray scale by adjusting the level of voltage from the liquid crystal which cannot completely block all light while the organic materials in OLED decompose when exposed to ultraviolet light not to mention the blue light.

Not deterred by these limitations, the LCD pushed out the rival displays of the brown-tube and PDP in the market, obtaining the honorable crown, and now it went on to prepare for the competition with a new display of OLED in full scale.

The picture quality of a display is determined by the three elements of contrast ratio, color gamut and resolution.

150202_[Analyst Column] CES2015에서 보여준 TV의 종착역은 명암비

 

The contrast ratio is the most basic information necessary for recognizing an object developed as a human evolves for millions of years. The human eye can distinguish an object only with a black and white shape at night without the moon and it also perceives a three dimensional space as a distant object is the information resulting from the difference between contrast ratios. But the human eye gets tired faster than any other organs. When a human gets tired, he/she closes his/her eyes to sleep and this action is to block the light from outside. For the bright lights like sunbeam blind the human eye that is susceptible to light, it is critical to avoid the exposure to direct lights around the eyes by wearing a hat with a brim in the open air. The sunglass functions in the same purpose.

Thought an office area uses bright florescent lights as a human gets active in a bright place, a house requiring comfort, high-end restaurant, hotel, etc. are recommended to take the brightness creating the appropriate shadows according to the position of the right sources. It is because a human body relaxes and feels comfortable through the eyes in the adequately dark environment. Furthermore, the human eye cannot detect the intensity of very bright light but the degree of darkness can be distinguished easily. Therefore, a TV that is most beneficial to a human body is a product made with the display that fully produces darkness. That is the OLED TV.

LCD always employed the notion of resolution as distinctive marketing strategy when competing with a brown-tube and a PDP in the market. It is due to the fact that the display with the higher resolution provides more information and the picture and video express smooth images. Though LCD had poor contrast ratio and color gamut than a brown-tube and the price also was relatively high, it grew rapidly indebted to the diverse contents like MS Office and the development of internet.

The emergence of OLED which has superior contrast ratio and color gamut than LCD and even the resolution equivalent to LCD became the biggest challenge for the LCD panel manufactures which have already made a huge investment. As LG Display is the only manufacturer capable of producing a large OLED panel with the 4K resolution, it is very urgent for the TV manufactures to secure the highest possible quality LCD TV to compete with the LG Electronics’ OLED TV.

The LCD TV made with the BLU using the quantum dot (QD) material got one step closer to the OLED TV obtaining the 100% of NTSC which was only available for OLED.

The key is the contrast ratio.

 

Choong-hoon Yi / Chief Analyst / UBI Research / ubiyi@ubiresearch.co.kr

LG Display, next is the plastic OLED!

Supported by the success of WOLED production for OLED TVs, LG Display is ambitiously formulating the next project with the plastic OLED. The development of dual-edge plastic OLED was completed as an extension of the plastic OLED product already used in LG’s G Flex and G Watch, and the product for automobile dash board is under preparation.

Presenting the curved plastic OLED display for dash board and dual-edge plastic OLED at the press conference exhibition hall of CES 2015, LG Display demonstrated its diverse products portfolio employing plastic OLED.

150130_LG디스플레이, 다음은 plastic OLED다!

 

LG Display CEO Han Sang-beom mentioned at the press conference that the dual-edge plastic OLED panel to apply for diverse customers and smartphones is under discussion and the product for a dash board is under development in close collaboration with two automobile companies. However, he also said that it may require more time as the display for an automobile demands brighter light quality and the clients are expecting to use it from 2017.

Though the original plastic OLED produced by LG Electronics for G Flex was only HD level resolution incompatible with other displays for smartphones, now the FHD plastic OLED for the G Flex 2 which was announced at CES 2015 secured enough competitiveness in terms of resolution compared to the LCD and OLED panels manufactured by other rival companies.

“A decision for investment will be made soon!” said Mr. Han at the end of the press conference regarding the plastic OLED line investment.

The size of the early investment is estimated to be Gen6 15K and the major clients for the plastic OLED panel will be LG Electronics and Apple.

Chung-hoon Lee, Editor, editor@olednet.co.kr

LG Chem. announces new OLED lighting product milestones

LG Chem announced today that it achieved two important milestones in the development of OLED lighting products with the start of manufacturing of the 320 x 320 mm OLED light panel, the world’s largest available in the market, and the completion of the research and development phase for a new plastic-based OLED light panel.

The 320x320mm OLED light panel is 0.88mm thick panel and has an efficiency of 60lm/W, CRI over 90, and has output levels of 800lm with a nominal input (8.5V 1,600mA). The panel’s output can reach 1,200lm which is similar to a common 60-75 Watt incandescent lamp. This is significant because it marks first time that OLEDs can be considered as an energy-efficient / human-friendly light source available for general purpose use.

With LG Chem having begun mass producing the 320x320mm panels in January, the panels can be ordered at $680USD per panel, with a lower negotiated price for bulk orders.

150128_LG 화학, 새로운 OLED 조명 제품 목표 발표1

 

LG Chem has also completed development of a truly flexible plastic-based OLED light panel and engineering samples are now available. LG Chem’s current bendable OLED panels (F6BA40, F6BA30) are thin-glass based that provides a limited bending radius of 75mm. The new flexible OLED panel has vastly increased the bending radius flexibility to 30mm because of the adoption of a plastic substrate for the panel, which also eliminates the danger of the panel shattering when excessive force is applied.

The main challenge of converting from a glass substrate to plastic was to maintain the performance levels of efficiency, luminance, and CRI. LG Chem has overcome this challenge by adopting its expertise in barrier and encapsulation technology.

The specifications of the LG Chem’s new plastic-based OLED light panel are 60lm/W efficiency, 75lm brightness, 3,000K in color temperature, and CRI over 85. Engineering samples are available at $250USD per panel. The mass production of the flexible panel is scheduled to begin in July 2015. The price will be adjusted accordingly once mass production starts.

150128_LG 화학, 새로운 OLED 조명 제품 목표 발표2150128_LG 화학, 새로운 OLED 조명 제품 목표 발표3

Universal Display and LG Display Announce Entry into Long-Term OLED Patent License and Supplemental Material Purchase Agreements

Universal Display Corporation (Nasdaq:OLED), enabling energyefficient displays and lighting with its UniversalPHOLED® technology and materials, and LG Display Co., Ltd. (NYSE: LPL), the world’s leading innovator of display technologies, today announced the signing of a new OLED Technology License Agreement and Supplemental Material Purchase Agreement. The agreements run through December 31, 2022.
Today’s announcement builds on a long-term relationship between the two companies. Under the license agreement, Universal Display has granted LG Display non-exclusive license rights under various patents owned or controlled by Universal Display to manufacture and sell OLED display products. In consideration of the license grant, LG Display has agreed to pay Universal Display license fees and running royalties on its sales of these licensed products over the term of the agreement. Additionally, Universal Display will supply phosphorescent materials to LG Display for use in its licensed products.
“We are excited to enter into these agreements with our long-term partner LG Display, a global technology innovator who is leading the charge for OLED TVs, evidenced by its recent CES showcase of new 4K models ranging from 55″, 65″ and 77″ in flexible, curved and flat form actors,” said Steven V. Abramson, President and Chief Executive Officer of Universal Display Corporation. “The growth of our relationship demonstrates the continued acceptance of our OLED technology and phosphorescent materials by the display industry for cutting-edge, high performance, energy-efficient commercial OLED displays. We look forward to the continued collaboration in support of LGD’s advancements in expanding the thriving OLED product roadmap, including the advent of new form factors that redefine what a display can and will be.”
“This is a win-win partnership for both companies. We expect this strategic alliance with Universal Display will bring synergies in accelerating the growth of OLED technology, and based on strengthened OLED business, LG Display is committed to deliver differentiated products to customers and the market,” said Sang Deog Yeo, President and Head of OLED business unit of LG Display.

[Analyst Column]The key technology to realize 8K OLED TV is transparent hybrid encapsulation technology

Choong-hoon Yi / Chief Analyst / UBI Research ubiyi@ubiresearch.co.kr

Along with LG Electronics, Panasonic and Skyworth joined the UHD TV industry as releasing the 55-inch, 65-inch and 77-inch UHD OLED TVs at CES2015.

In response to this, the LCD TV manufacturers unveiled numerous new LCD TVs at CES2015 combining different technologies of QD, HDR, and curved design.

OLED is catching up with LCD in terms of resolution and LCD began to compete with OLED in respect of curvature and color.

There were competitions with regard to resolution between OLED and LCD in the history of smartphones. As the resolution of small and medium LCD improves in order to distinguish itself from OLED starting from 200ppi in 2010 to over 500ppi through the Retina (326ppi), OLED accomplished the equivalent resolution through the FMM mask and pentile technologies.

The LCD TV industries are anticipated to develop products with ultrahigh resolution in consideration of the small and medium OLED. And the OLED TV industries are reviewing the technologies to answer to this trend of ultrahigh resolution.

The resolution over 8K is available for OLED TV by either converting the bottom emission structure which is currently applied to the existing 4K OLED TV to the top emission structure with higher aperture ratio or producing the RGB OLED panel with the solution process.

Sony already developed and introduced the world’s first 4K OLED TV with the top emission technology at CES2013. Employed for Samsung Electronics’ Galaxy series, the top emission structure can be applied to a large area but the complication is in the transparent encapsulation.

보도자료사진_1영문

 

It is hard to use the frit technology currently used in small and medium to a large OLED for its durability issue. The hybrid encapsulation method using the transparent encapsulation film emerges as the optimum alternative and the developments are set in that direction.

The substantial market growth is expected as the transparent hybrid encapsulation technology is critical in realizing a large area flexible OLED and transparent OLED besides the ultrahigh resolution using the top emission.

 

 

보도자료 사진_수정_영문

Feast of Plastic OLED

LG Electronics unveiled its secret weapon, G Flex2 at CES2015. Produced with the plastic OLED from LG Display, the smart phone G Flex2 features relatively enhanced resolution from the HD level resolution to FHD (403ppi) though the display has reduced from 5.99-inch to 5.5-inch when compared to the existing G Flex released in 2013.

150123_Plastic OLED의 향연1 150123_Plastic OLED의 향연2 150123_Plastic OLED의 향연3

G Flex2 is the up to date curved smart phone equipped with the latest 64bit Octa-Core CPU and Snapdragon 810 processor from Qualcomm. The frontal curvature of 700R is also the same as in the G Flex, but the backside is 650R, increasing the sense of grip. For its 700R display, it provides much better sound quality by reducing the gap between the user’s face and the phone. With the self-healing back cover as in the G Flex, it just removes various scratches occurred in daily life. 

LG Electronics and Samsung Electronics sold the curved smart phones in 2013 at the same time. LG Electronics’ G Flex was the same panoramic design as now but Samsung Electronics competed by releasing a smartphone curved from left to right to emphasize a firm grip.