Technology, Process and Cost
Mini-LED Backlight Unit in neo QLED TV Samsung
By Yole SystemPlus —
In depth technical and cost analysis of the first TV mini-LED backlight unit and its assembly
Key Features
- Detailed optical and SEM photos
- Precise measurements
- Materials analysis
- Manufacturing process flow
- Supply chain evaluation
- Manufacturing cost analysis
- Estimated selling price
- Comparison between Samsung TV and Apple iPad Pro
After more than three years of hype, excitement, and unfulfilled promises, mini light emitting diode (LED) backlights are finally ready for primetime. Properly designed miniLED backlights allow Liquid Crystal Displays (LCDs) to reach contrast performance close to that of organic LEDs (OLEDs), while maintaining the high brightness characteristics of LCDs. They offer reduced power consumption, a very thin form factor, and cost and price competitiveness with OLEDs. MiniLED monitors and laptops have been available since late 2020, but in 2021 with this newest Neo QLED 8K model, Samsung is really bringing this newer large TV display technology to the consumer. This System Plus Consulting (SPC) teardown report provides great insights into Samsung’s choices.
In this report, SPC provides a full reverse costing study of the miniLEDs and their assembly in the backlight unit of the TV display in the 65-inch 2021 Neo QLED 8K.
The backlighting system is composed of 12,096 miniLEDs divided into eight panels of 1512 miniLEDs. Each panel integrates 168 dimming zones.
- The miniLEDs, which are GaN-based dies on patterned sapphire substrates, have an engineered light-emission pattern using dedicated top and back dielectric reflectors. We think that they are manufactured by San’an Optoelectronics in China.
- We believe that the chip-on-board assembly of the more than 1,512 miniLEDS is done by Samsung in Vietnam. The miniLEDs are mounted in flip-chip configuration.
- The miniLEDS are driven by 42 driver dies from Samsung. These drivers are wafer-level chip-scale packaged.
This report provides insights regarding technology data, manufacturing cost, and selling price of the backlight unit, with a focus on the miniLEDs and their drivers. A comparison between the Samsung TV and the Apple iPad Pro shows the different technology choices.
Overview / Introduction
- Executive Summary
- Reverse Costing Methodology
- Glossary
Company Profile & Supply Chain
- Samsung
- Supply Chain
Teardown Analysis
- TV Overview
- TV Opening
Physical Analysis
- Backlight Unit
- MiniLED
- Die Overview
- Die Cross-Section
- MiniLED Driver
- View & Dimensions
- Delayering & Main Blocs
- Die Process
Manufacturing Process Flow
- MiniLED Front-End Fab Unit
- MiniLED Front-End Process
Cost Analysis
- Supply Chain
- Yield Hypothesis
- MiniLED Cost
- LED Front-End Cost
- LED Die Probe Test and Dicing
- LED Wafer and Cost
- MiniLED Driver Cost
- Front-End Cost
- Probe Test, Thinning and Dicing
- Dies Cost
- Backlight Unit Cost
- Complete Unit Cost
- Complete Unit Price
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