A: We consider that there are two aspects of the problem, one is a technical problem, and the other is an ideological problem.
On technical issues
We believe that the general root cause of the technical problems of the traditional LED display panel industry is that the packaging technology uses brackets and pins. The incongruity of industrial chain technology caused by the theoretical defects of bracket-type independent device packaging technology has exposed a variety of serious industrial problems. These unsolvable problems have become an insurmountable gap in the direction of the traditional LED display panel technology towards the small-pitch, micro-pitch, Mini LED, 4K and 8K ultra-high-definition video display industry.
Theoretical defects in the packaging technology of bracket-type stand-alone devices
The theoretical defect of bracket-type independent device packaging technology comes from the packaging link of the traditional industrial chain, and the original logic motivation of using brackets and pins is to simplify and reduce the technical difficulty of the packaging process, and it is easy to achieve standardization, scale and automated production. Compared to COBIP technology, bracket-type packaging technology believes that the production process does not have the problem of "one-pass rate". Standing in the packaging technology link, you will find that this technical theory is almost impeccable and perfect, but from the perspective of the traditional LED display panel industry chain, you will find that its theory is unreasonable, limited and contradictory, resulting in the following major industrial technology problems that cannot be ignored:
1. The one-time pass rate problem is expanded
In the traditional industrial chain packaging link, although the use of brackets and pins, simplifying and reducing the difficulty of the packaging process, seemingly cleverly dodged the "one-pass rate problem" of the production process, but this problem was extended to the display companies downstream of the industrial chain. Display companies purchase stand-alone packaged devices with bracket pins from packaging companies, and then SMT to the driver board, the first "one-pass rate problem" will occur. If the product is applied outdoors, the bracket pins of the packaged device need to be coated with glue protection, and there is a second "one-pass rate problem" in yield detection. Therefore, the problems ignored by the packaging links of traditional industries have caused major harm to the industrial chain, and the problems have been expanded and more serious.
2. There is a paradox in the industrial chain
The failure efficiency indicators of independent packaging devices given by traditional industry chain packaging companies are often in the million level, and will not be lower than 10ppm. But why is it that if the screen enterprise makes a panel-level (module) product, the pixel runaway rate index will be reduced to 10,000 or 1,000 levels? For more than 30 years, no matter how hard the industry tries, the indicator of the LED display panel produced by the screen company has never broken through the million level, let alone reached the million level, which is the paradox phenomenon we found. The more strange phenomenon is that when screen companies and packaging companies promote technology and products, they often like to quote the machine failure rate indicators given by packaging companies to talk about things, but the machine failure rate indicators and the LED display panel pixel runaway rate indicators are not the same concept at all. Why can't the products created by our traditional industrial chain go from millions to millions, but only millions to tens of thousands? Why is there such a big gap with the LCD industry? If you don't think about this problem, you can't see any problems with traditional packaging technology, but isn't it strange that the problems shown by industry logic are there? We think there must be big problems here.
3. The contradiction between the upstream and downstream of the industrial chain is becoming increasingly prominent
Due to the use of bracket pins in traditional packaging technology, the quality of led display panel product batches of downstream enterprises is unstable, and the feedback information is easy to cause misjudgments to downstream enterprises, which increases the difficulty of manufacturing and risk control of downstream enterprises. Even if the same batch of bracket-type independent packaging devices, in the process of transferring to downstream enterprises, will face the length of logistics paths, differences in climatic conditions, the level of quality control and production control capabilities of screen enterprises, the advantages and disadvantages of production equipment, etc., which will cause huge quality differences. When the project has problems, the screen enterprises and packaging companies blame each other, it is difficult to find the problem and fair treatment plan, gradually deepening the contradiction between the packaging enterprises and the screen enterprises, and eventually leading to the total outbreak of contradictions, packaging companies no longer supply screen enterprises, their own production of display panel products, this move is really a helpless passive vertical integration behavior. The recent moves of packaging giants in certain industries have illustrated this. After the integration, this kind of industrial problem caused by the bracket pin still exists, and it cannot be solved, and the problem can only be carried by itself.
4. The waste of high-quality resources in the industry is serious
The packaging link of the traditional industrial chain gathers a large number of high, fine, and sharp packaging equipment, high-quality technical personnel and strong industrial capital, which can be used to produce million-level LED display panel products, but due to the defects of the bracket-type packaging technology theory, the LED display panels created by downstream enterprises are low-level manufacturing products that cannot exceed the tens of thousands, which is a serious waste of industrial resources. Any optimization and improvement in the packaging technology of bracket-type independent devices is still a low-level to low-order technological transformation, which cannot be the full use of industrial resources and the correct investment direction of industrial capital, and will eventually cause a serious waste of industrial resources. In addition, the technical advantages of upstream LED chip companies cannot be exerted in the industrial chain dominated by traditional packaging technology, which is actually a waste of chip material resources.
5. Water-intensive, electricity-intensive, raw material-based, serious sewage discharge of industrial technology and industrial supporting technology
Compared with the de-stent integrated packaging technology, the bracket and pin material cannot be eliminated, and a highly polluting plating process is required. The use of brackets and pins, it can only be 2 plates of lamp drive separation panel integrated manufacturing technology, than 1 plate of lamp drive integrated panel integrated manufacturing technology more than 1 times the amount of printed circuit board, printed circuit board is LED display panel and LCD display panel indispensable raw material supporting industry, high water, electricity, energy industry, but also heavy pollution emission industry. In addition, the degree of industrial integration is low, some production process links cannot be saved, and energy waste is particularly serious.
On the question of ideas
In the initial stage of the industry, according to the level of industrial manufacturing, supporting equipment, material technology and process technology at that time, the bracket pin packaging solution was the logical starting point of technology. However, with the technological progress in all aspects, especially the emergence of COBIP technology, the industry is still unable to make effective reflection and review in the face of emerging industrial technology problems, product problems and project case problems. The packaging link continues to engage in the totem worship of bracket pin technology, and misleads the optimization and improvement measures for the bracket-type independent packaging devices to the bracket pins, ignoring the existence of disastrous industrial problems brought to downstream enterprises, we believe that packaging companies must bear at least 70% of the moral responsibility, and the other 30% should be borne by downstream display companies. The reason is: after so many years, our screen companies have never questioned: "Why did your packaging factory sell me a 10ppm independent package device with machine failure efficiency, and I can't use it to make a million-level display panel product"? It is a matter of thought to go against the grain and do what is given. The ideological problem is expressed in 6 words: it is "heavy technology and light industry", which means that only attention is paid to the development and breakthrough of industrial technology, and does not pay attention to the research of industrial technology problems, which will eventually make the development of the industry unclear, the foundation is not solid, and the stamina is insufficient.
Popular science tips:
1. Crash efficiency indicators
The index is an important production index provided by the bracket-type independent device packaging factory to the downstream LED display enterprises, generally not less than 10ppm, which means that when the screen enterprise uses the SMT process to solder the bracket-type packaging device to the driver PCB circuit board of the module, when the test is lit, the failure problem of one million lamp beads cannot be more than 10, which belongs to the production process control indicators.
2. LED display panel pixel runaway rate indicator
The index is the LED display or display panel manufacturing enterprises to provide the end customer with the use of products in the process of evaluation indicators, generally in the specification standards stipulate led display or display panel in the factory indicators and how much time customers use the product to maintain in what range of indicators. For example, 5.1.8 in the "Mini LED Commercial Display General Technical Specification" has made million-level provisions on the pixel runaway rate index of mini LED display at the factory and the pixel runaway rate index after 10,000 hours of cumulative use, which is a product use evaluation index. If the indicator does not meet the standard agreement, the consumer can claim compensation from the manufacturer accordingly.
Therefore, the meaning of the machine failure efficiency indicator and the meaning of the pixel runaway rate indicator are completely different, and the indicator that consumers get when purchasing the product must be the pixel runaway rate indicator. This indicator is very important, which is related to whether the LED display manufacturer has a high-end manufacturing technology or a low-level manufacturing technology, or a medium-level manufacturing technology. At present, only the intermediate manufacturing and high-end manufacturing technologies of LED display panels can meet the million-level pixel runaway rate standard of the product.
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