LED Displays are Not the Same

Apr 10, 2021 | knowledgebase | 1 comment

LED displays are comprised of many components. Various commercial manufacturers around the world may or may not state these components in their quotations. You may see items such as framing, power supplies, controller cards, video processors, cabling, mounting/hanging points, or display interface units either included in the bottom line or broken out as separate line items in a quotation. One word of caution before we focus on the piece of the display with the most points of differentiation. If you are comparing pricing, make sure you are aware of all the components required to make the display operational in the environment for your solution, and make sure you’re comparing apples to apples when reviewing quotations. One bottom line price may include everything you need to be operational whereas a second may be the price just for the LED panels, you don’t want to find out the fact after the order sealed, at the end you are paying more.

LED Diode 

The core of led display LEDs are diodes – meaning they are semiconductors. They are the most important unit for a led display and takes on 50-60% of the total cost. The two main types of LEDs presently used for lighting and display systems are aluminum gallium indium phosphide (AlGaInP, sometimes rearranged as AlInGaP) alloys for red, orange, and yellow LEDs; and indium gallium nitride (InGaN) alloys for green, blue and white LEDs. Slight changes in the composition of these alloys change the color of the emitted light. The actual chips/dice/wafers of the (LED) manufacturing process are basically the same the world over. What makes one manufacturer’s diode better than another is basically the consistency of the manufacturing process, the predictable, repeatable processes rendering consistent yields. This is accomplished by rigid manufacturing standards, “Six Sigma” processes, purity of chemical elements, etc. Diode manufacturers in the industry gain a reputation for delivering consistent and reliable quality. If you’ve been in this industry for a minute or two, you know the names that always come up when discussing quality. One starts with an “N” and one starts with a “C”. That being said, there are other contract manufacturing companies whose process is being guided and refined by the display manufacturers, which are turning out diodes of comparable quality.

led display price and cost

Just as with any consumer or commercial goods we buy, the reason some products cost more than others owes to labor and shipping costs, and the quality of the materials used. There are cheap TVs at Walmart, and premium TVs at Best Buy. They do the same thing, but what’s inside the housing can be different. On a direct-light LED circuit board, is a grid of attached pixels – or the smallest addressable components on the display from the perspective of content delivery. These “pixels” typically are what is referred to in the industry as a “package” and as you might expect, given the name, these are comprised of several individual elements – all of which can be differentiators in the performance and efficiency of the display. The quality and type of wiring used, the circuit board backplates, the epoxies, and numerous other things affect the final price of display electronics, as well as performance and reliability.

The actual chips/dice/wafers of the (LED) manufacturing process is basically the same the world over. What makes one manufacturer’s diode better than another is basically the consistency of the manufacturing process, the predictable, repeatable processes rendering consistent yields. This is accomplished by rigid manufacturing standards, “Six Sigma” processes, purity of chemical elements, etc. Diode manufacturers in the industry gain a reputation for delivering consistent and reliable quality. If you’ve been in this industry for a minute or two, you know the names that always come up when discussing quality. like Nichia and Cree. There are other contract manufacturing companies whose process is being guided and refined by the display manufacturers, which are turning out diodes of comparable quality. Pay attention to the spec of the LEDs, even for those LEDs comes from the same vendor, they have different level quality, it mainly depends on the material and technology that made of LED: Wire bonding, Reflector, Glue.

Package Design

LED PACKAGE SMD

Package Quality

The actual chips/dice/wafers of the (LED) manufacturing process is basically the same the world over. What makes one manufacturer’s diode better than another is basically the consistency of the manufacturing process, the predictable, repeatable processes rendering consistent yields. This is accomplished by rigid manufacturing standards, “Six Sigma” processes, purity of chemical elements, etc. Diode manufacturers in the industry gain a reputation for delivering consistent and reliable quality. If you’ve been in this industry for a minute or two, you know the names that always come up when discussing quality. like Nichia and Cree. There are other contract manufacturing companies whose process is being guided and refined by the display manufacturers, which are turning out diodes of comparable quality. Pay attention to the spec of the LEDs, even for those LEDs comes from the same vendor, they have different level quality, it mainly depends on the material and technology that made of LED: Wire bonding, Reflector, Glue.

Bond Wire

Gold, copper, Iron The conductor and wire bonding in the package is the apparatus which, as you might suspect, transfers electric current from the circuit board to the diodes. Conductors are located on the underneath or backside of the package carrier and consist of an anode and cathode division (positively and negatively charged). These pieces are manufactured from one of three different metals – gold, zinc, or silver. The lining within the diode’s package cavity on the front of the package is referred to as the reflector. This comes in variations of two colors – either black or white. As you might suspect, white or whiter colors of reflectors better reflect, and more efficiently channel, the light from the diode outward away from the package. Black or darker reflectors tend to absorb more of the light from the diodes. The actual shape of the reflector cavity has much to do with the quality of the image and brightness. learn more about wiring bonding material.

Reflector

This will be discussed further when we discuss fill ratios. While we’re discussing the coloration of the reflector, it is also a good time to talk about the face of the package itself. These also come in various gradients of white and black and serve a similar function as the reflector. As a general rule of thumb, both of these elements either serve to enhance brightness (whiter elements) or to enhance contrast (blacker elements). Black face LED packages typically are better when the preferred result is for greater image detail. White and lighter face LED packages are preferred when brightness is a key requirement for content delivery – such as combating hostile ambient light conditions. Package faces also come in different finishes, matte finishes, glossy, and variations in between. We’ve talked about all of the components of major differentiation within the LED package sans one.

Len

The lens. The lens of the package is comprised of an optically translucent sealer material – most commonly silicon – which fills the cavity housing the diodes. The lens composition, as you might guess, affects to a greater or lesser extent, the optical performance of the package. Counterintuitively, a certain amount of opacity within the lens material actually enhances overall image quality for the average human viewer with 20/20 vision.

LED Display White Paper

Apr 10, 2021 | knowledgebase, quality assurance | 1 comment

Video walls can create stunning centerpieces for a variety of spaces. LED video displays can transform any environment, but you may become overwhelmed when you look at all the options on the market. There are many elements to consider when selecting video screens, including indoor vs outdoor, pixel pitch, front vs rear serviceability, and shape. how to select led displays that fit your project and getting a good supplier to manufacture your led screen is a pain in the ass for importers.
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led display screen white paper

Why this guide?

The prospect of purchasing commercial digital display solutions is daunting, in no small part due to the complexity of ever-changing industry jargon. The fluidity of many of the industry’s most common –yet most confusing- specifications can make the precise definitions of these terms quite difficult to pin down. Due to the complexity of the LED screen, ever-updating technologies, increasingly intense competition, and flooded suppliers’ information, it is getting more difficult to find or choose the right products and suppliers.

Understand the industry

Most LED display manufacturers worth their salt can talk a good game. As someone who has spent almost 15 years in the digital display industry in the marketing/communications space, we know this well. Sales and marketing teams throughout our industry – hell, all industries – tout their products and services using brand names slogans, and feel-good video productions. Some companies actually back up their talk with quality products and services. Others back it up with… well, not-so-quality products. Still, others back up their talk with others’ products and services, but that’s a grievance for another day. 
But we have to admit if you’re new to the digital display industry or unfamiliar with some of its finer, technical aspects, the company that talks a good game is probably indistinguishable from the company that has a good game. That’s a problem for you. (And for good companies.)
Many consumer advocates agree that if it’s tough to distinguish between companies based on what you see and hear from them. and they are most likely to find out that a majority of the product is basically the same(design), while the price varies.

Understand the specification and get what you want 

There are not many LED display manufacturers in the industry who can make innovations and develop new technology, the only way for them to attract customers is to tag a really “sweet” price. they look the same (appearance), and the spec is just close or even the same as others who offered a higher price. in that case, most of the customers would pretend to have a “sweet” price. but the truth is they are not the same, they even look like twins. Whether it is good or bad quality, the majority of the products can work properly for a few months, after the honeymoon, troubles come up from time to time. you are not getting what you really look for, a decent quality. You are not getting what you paid for sometimes, you actually paid a reasonable price and you don’t get what you paid for. even an experienced importer would just pay attention to the LED  and IC, that is right, they take up more than 60% of the cost of the screen. while there are many other ignored component or design contributes a lot to the quality of the display. Manufacturers can exploit an advantage of those “vague and unclear” to make more profit. what’s worse, they may replace LED A with LED B. the fiercer competition makes those factories rack their brains to cut down the cost of raw materials.
led display white paper

Accurate information matters

Are all factories are all different, Are all the led displays basically the same? if so why the price could be so different from one supplier to another .you may probably say that the suppliers will sacrifice a part of the profit to sell more, and keep the quality, It is true, by a very small chance if they make a promotion of the year. What customers need to realize first is that there is no real governing body judging how specifications are created, claimed, and tested, so manufacturers can pretty much say anything. With no authority monitoring what display providers can and cannot claim, customers have to shoulder this fact-checking responsibility themselves. There are a few steps in this process. First, the absence of regulated standardization within the industry does not preclude the existence of informal but commonly-met benchmarks. For each display metric, customers should learn these benchmarks and use them to set their initial expectations.
Next, customers should research the intricacies of each specification so they can smoothly counter sales speak with actual knowledge. The final step is to request that manufacturers test and prove their claims. Accurate information (to make an apple to apple comparison) is the key to evaluating the quality and performance of any manufacturer’s LED DISPLAY. Be sure to ask your vendors for all the components (which we will discuss later), and get as many details as possible. Understanding the fundamentals is probably the best way to make sure you’re on track to get the value you desire. The more you act like a veteran, the less chance you get fooled (not kidding ). The best way to reduce the risk is to set up an “office” in China or hire an experienced QC, to help you with the sourcing and inspection. or find a third party to make the inspection for sure, it won’t cost much but do save you a lot of time & money.
In this led display white paper, we discussed the basic components: less, driving ic, cables, cabinet design, to see what makes a good quality led screen, and how it contributes to the led display. 

Contact us for a 33 pages free copy white paper 

CHOOSING THE RIGHT LED DISPLAY!

Mar 24, 2021 | ledtips | 1 comment

CHOOSING THE RIGHT LED DISPLAY!

Video walls can create stunning centerpieces for a variety of spaces. LED video displays can transform any environment, but you may become overwhelmed when you look at all the options on the market. There are many elements to consider when selecting video screens, including indoor vs outdoor, pixel pitch, front vs rear serviceability, and shape. If you aren’t sure where to start, VISIONPI has products to fit every need.

So Many Video Wall Options—Where to Start

To get started, it’s essential to understand the basics. Here are some fast facts you should know:

  • An LED (light emitting diode) is a semiconductor device that emits visible light when an electric current passes through it.
  • LEDs require much less power than other types of screens powered by incandescent lamps, offering greater efficiency and a longer lifespan.
  • Indoor LED screens have wide-viewing angles, no color shifts, and have a smooth appearance from a short distance.
  • Outdoor LEDs are weather-proof, very bright, and are ideal for longer viewing distances.
  • Brightness is a key element in designing your video wall and is measured by nits. Indoor LEDs typically have 1000-1500 nits while outdoor LEDs have 2000-3000 nits. A nit is almost 3.5 times brighter than a LUX, the measurement of brightness used by projector screens.
  • Pixel pitch is another important part of LED selection. Pixel pitch is the physical distance from the center of one pixel to the next, measured in millimeters. The higher the number, the fewer pixels, and lower resolution. Depending on viewing distance, you’ll need to determine the right pixel pitch for optimal resolution. A general rule is 3.28 feet per 1mm of resolution.
  • Cost and budget are always a consideration. LEDs have a higher initial investment than projectors but last much longer.

Finding the Right Video Wall Equipment for Your Project

If you aren’t an AV expert, selecting the right LED video wall may seem difficult. It’s important to educate yourself on the basics of LED screens, as provided above. This gives you a foundation to begin your search. As you work with those that have specific expertise, like VISIONPI, you’ll know the right questions to ask about pixel pitch, brightness, and longevity.

To narrow down your selection, ask these questions:

  • How will you use the display? Does it need to be the central element in a setting? Or is it a backdrop?
  • Are you using the displays inside or outside?
  • Will it be viewed from long or short distances?
  • How will it be mounted? Does the area require a certain shape or curvature of the screen?

Depending on your answers, you can narrow down exactly what you need to bring your ideas to life.

Products for Every Video Wall

VISIONPI has a large variety of award-winning LED displays. We can create nearly any size or shape screen required. From indoor to outdoor to curved configurations, there’s a perfect product for every installation.

You may have specific goals for your video walls—attracting attention, upselling, increasing curb appeal—and our team of experienced professionals will help you reach that goal. As a full-service LED provider, we collaborate with customers creatively to ensure the best experience.

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LED Display Wiring Bondings

Apr 10, 2020 | knowledgebase, Technology | 0 comments

What is wire bonding?

The conductor and wire bonding in the package is the apparatus that transfers electric current from the circuit board to the diodes. Conductors are located on the underneath or back side of the package carrier and consist of an anode and cathode division (positively and negatively charged). These pieces are manufactured from one of three different metals – Gold, Copper, silver, or even Iron. Copper Wire bonding refers to the wire bonding process that employs copper wires for interconnection, instead of the gold and aluminum wires traditionally used in semiconductor packaging.

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LED architecture and design concepts

Wire bonding material

There are variances in both conductivity and environmental performance with these three metals.

Gold is the preferred metal for both situations, having both the best conductivity and being the most environmentally resistant – but as expected it is also the most expensive.

Silver/ Iron is the most susceptible to corrosion and Copper is not gold and it is unreasonable, given the different physical and chemical characteristics of each metal, to expect copper simply to bond in the same way as gold. From a performance point of view, copper can be as reliable as gold wire but copper is facing problems in more challenging stress tests such as temperature cycling, If you are in an indoor environment naturally this isn’t usually a concern with controlled, low-humidity.

For this moment, gold wire still is the more stable one for the LED display. While larger-diameter copper wire has been utilized in many applications for some considerable time, the copper bonding wire is not a ‘drop-in’ solution for gold wire and should not be seen as such in fine and ultra-fine pitch applications. Copper wire from different suppliers can differ considerably in purity and mechanical properties during the process. That is why, for small pixel pitch, normally Gold wire is adapted.

How to Choose Between Copper and Gold Wire Bonding for LED Video Displays

Copper VS Gold Copper Wire bonding refers to the wire bonding process that employs copper wires for interconnection, instead of the gold and aluminum wires traditionally used in semiconductor packaging. Copper is rapidly gaining a foothold as an interconnection material in semiconductor packaging because of its obvious advantages over gold. These advantages include:

wiring bonding engineering tensile stress
  • 1) Cost reduction of up to 90%;
  • 2) superior electrical and thermal conductivity;
  • 3) less intermetallic growths;
  • 4) Copper also has about 25% higher thermal conductivity than gold ,greater reliability of the bond at elevated temperatures;
  • 5) higher mechanical stability

 

 

  • The disadvantages of copper wires versus gold wires include the following:
  • 1) copper tends to undergo oxidation at relatively lower temperatures;
  • 2) the hardness of copper wire require bonding parameter (bond force and ultrasonic energy in particular) optimization to achieve effective bonding without causing cratering;
  • 3) copper wire introduces a few failure analysis difficulties; 
  • 4) being relatively new, copper wire bonding technology is not yet as well-understood as gold ball bonding technology.
gold copper led wiring bonding
Cu and Au bonding wire

Nationstar Gold wire bonding ReeStar Series

A. ReeStar ™ (“RS”), a high-end full-color display device launched in 2013, mainly has four models, is a high-end brand of indoor foreign star high quality LED screen, more than three years warranty, excellent performance can fully realize the led high-definition display, high contrast ratio, high waterproof, high reliability, low light decay and other requirements. requirements.

B. 7 Major Performance Advantages of RS

 •  a). Waterproof and moisture-proof: waterproof performance reaches IPX8 level; moisture-proof performance reaches MSL 2a level.

 •  b). Cold and thermal shock resistance: high bonding of packaging materials, -65℃~+150℃ cold and thermal shock without dead light.

 •  c). Anti-back pressure: meet the high refresh frequency demand, 85 ℃, 85% RH, simulated back pressure test without failure.

 •  d). Salt spray resistance: the use of a wide range of simulated seaside corrosive environment without dead lights.

 •  e). UV resistance: UV experiments accelerated aging outdoor simulation using 3 years, light decay is less than 20%.

 •  f). Low light decay: high temperature and high humidity accelerated aging simulation of outdoor use for 3 years, light decay <20%.

 •  g). High brightness: the highest brightness level in the industry.

C. RS’s 3 Major Appearance Advantages

 •  a). Matte surface, high contrast.

 •  b). Surface luminescence technology: turn point into surface, solve the problem of led glare.

 •  c). Low pin technology: high cup and short foot, easy for customers to fill glue and cover mask.

D. There Are 4 Main Models

RS-1921MBAR, RS-2020MBAM, RS-2727MWAS, RS-3535MWAR

Price difference between copper wire bonding and gold wire bonding

Copper is inherently 2 to 5 times cheaper than gold, so substituting gold wires with copper wires can realize tremendous annual cost savings for a semiconductor packaging company:

let’s do simple math, you will see how much difference in price among those LED of varied bonding material: For example： P10, 10,000 Pixels/sqm with Nationstar LED 3535: Gold wire: High brightness: 20USD/K Copper Wire: Normal brightness: 10 USD/K Iron Wire: 5USD/K So Basically you can see the price difference, gold wire is about twice of copper. When it comes to indoor LED with a smaller pixel, the price can be a huge difference. if you see P2 (250,000 pixels/sqm),nationstar gold wire 1010 is roughly 8 USD/K.while copper wire is 4 USD/K. so it is about 1000 USD more. Most of the time factories /salespeople won’t tell you about the wire bonding material, unless you ask, even you ask, they can lie, because this no way you can recognize the difference by your eyes. except for chemical lab testing. Visionpi has a long term partnership with Nationstar/Kinglight, we provide verification service to our customers.

Conclusion

copper and gold wire bonding are both widely used techniques for connecting LED chips to external circuits in the LED video display industry. Copper and gold wire bonding have distinct advantages and disadvantages based on their intended use. Copper wire bonding is an economical choice that offers high thermal conductivity but has limited lifespan and low electrical conductivity. On the other hand, gold wire bonding, which is more expensive, provides thin wires and high electrical conductivity while having low thermal conductivity. Ultimately, selecting between copper and gold wire bonding should be based on the specific needs and requirements of your LED video display project.

Verification Service:

Accurate information is the key to evaluating the quality and performance of any manufacturer’s LED DISPLAY. However, there are some manufacturers, who produce and sell LED MODULES in a large quantity, and they usually sell to other LED factories/companies.they are using mainly are iron wire bonding led (Mulinseng, HongSeng), for price sake. The competition is getting fiercer, there are small companies who sell inferior quality LED but claim to be a good one. Even now you know those brands and quality level. but you are unable to tell if it is real. After a few months running, the display will bleed you on the maintenance cost. Visionpi provides LED verification services, we can be your professional QC team to help you with the sourcing and inspection and bring lower purchase cost and guaranteed quality.check more our services.

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