Category Archives: FPDs and TFTs

August 14, 2012 — Following a sharp 30% drop during Q1 2012, worldwide shipments of flat-panel televisions returned to growth in Q2, according to a preliminary estimate from the new Worldwide Monthly TV Tracker issued by Displaybank, a business of IHS.

Worldwide shipments of flat-panel televisions, a category consisting of liquid crystal display (LCD) and plasma sets, rose to 48.9 million units in Q2, up 3.6% from 47.2 million from Q1.

Figure. Preliminary IHS estimate of quarterly flat-panel television shipments, based on data from the Worldwide Monthly TV Tracker.

“After an unusually weak start to 2012, global television shipments showed some signs of life,” said Tom Morrod, senior analyst and head of TV technology at IHS, adding that the seasonal post-holiday TV sales drop was “unusually sharp” in 2012 because of “tentative consumer spending.” Q2 is following normal seasonal patterns, with likely growth continuing in Q3.

Q2 started off on a strong note, with shipments in April rising by 4% from March to reach the highest levels of the year up to that point. While shipments declined slightly in May and June, the increase in April was sufficient to drive growth for the entire quarter.

Worldwide LCD TV shipments increased 3.4% in the second quarter, following a 29.3% drop in Q1. While worldwide plasma shipments are generally declining, they enjoyed a 6.6% bump in Q2, compared to a 39.5% plunge in the previous quarter.

In the LCD segment, which accounts for the overwhelming majority of flat-panel display (FPD) shipments, Samsung Electronics Co. Ltd. remained the leading brand in the Q2, according to the preliminary estimate. Samsung was responsible for 19.2% of unit shipments, down just slightly from 19.3% in Q1. LG Electronics held its second-place ranking with a 13.2% share of shipments, unchanged from Q1.

Table. Preliminary global Q2 LCD TV ranking (Percentage market share based on unit shipments). SOURCE: IHS Displaybank, August 2012.

Q2 Rank

Brand

Q1 Market Share

Q1 Market Share

1

Samsung

19.3%

19.2%

2

LG

13.2%

13.2%

3

Sony

8.4%

7.9%

4

TCL

5.9%

6.5%

5

Toshiba

5.7%

5.8%

 

Others

47.6%

47.4%

 

Grand Total

100.0%

100.0%

Samsung has “shrewd marketing, global distribution and efficient production” in its corner, Morrod observed. “Both Samsung and fellow South Korean brand LG are able to undercut their Japanese rivals on pricing, allowing them to retain their leadership. And with the Japanese market contracting dramatically, the companies based in the country have struggled to find new volume sales opportunities elsewhere.”

The strongest performance among the Top 5 was posted by No. 4-ranked TCL Corp. of China, which increased its share of shipments to 6.5 percent, up from 5.9 percent in the first quarter.

“TCL is prospering both because of overseas sales, which were up by about 150,000 units in the second quarter, and due to domestic Chinese sales,” Morrod said. “The company is taking advantage of capitalizing on rising sales in China in addition to upping its stature abroad.”

IHS (NYSE: IHS) provides information and insight in critical areas that shape today’s business landscape, including energy and power; design and supply chain; defense, risk and security; environmental, health and safety (EHS) and sustainability; country and industry forecasting; and commodities, pricing and cost. Learn more at www.ihs.com.

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August 13, 2012 — In 2011, light emitting diodes (LEDs) were expected to grab market share from cold cathode fluorescent lamps (CCFLs) in the display backlighting segment. However, prices for CCFL-backlight TVs fell alongside prices for LED-backlit TVs, and consumers preferred lower-cost models. Now, CCFL raw materials costs have exploded, setting the stage for market share grabs by LEDs, albeit later than expected, reports Jimmy Kim, DisplaySearch.

Rare-earth metals, the main raw material for CCFL phosphors, saw 5-10x higher prices from 2010 to 2011. As a result, the price of phosphor also jumped, rising to about 6x the price in 2010.

Figure 1. Prices for rare earth metals and phosphors for CCFL.

This price increase could lead to a scale-down of CCFL production and a lower utilization rate, which will push CCFL unit prices higher, further closing the price gap with LED units.

In 2011, most Japanese CCFL makers had already shed the CCFL business, seeing lost cost competitiveness. Korean and Chinese CCFL makers took the opportunity to fill higher-than-expected CCFL demand. The large scale production enabled by the concentrated purchase orders helped them hold the CCFL unit price stable, even under the increasing raw materials cost.

During 2012, the market situation grew worse for CCFL makers. TV makers introduced new low-cost direct LED-backlit TVs for the entry TV market segment. They plan to increase their sales allocation to these new products, which will lead to a further decrease in demand for CCFL. CCFL panel shipments are expected to decrease more than 40% Y/Y after Q2 2012. In 2011, the decrease was 30% Y/Y. This means that the scale-down and lower utilization rate for CCFL production seems inevitable this year.

Figure 2. CCFL panel shipments.

CCFL prices for some new models increased in Q2. Regardless, there have been almost no changes in CCFL prices for running models. The decrease in CCFL demand caused by the low-cost direct backlight TVs has led to a rise of CCFL unit price. This will probably lead to a further decrease in CCFL demand. We also expect that the EOL of CCFL-backlit LCD TVs will be accelerated.

This full article was published by Jimmy Kim in the DisplaySearch Monitor, August 2012. Learn more about DisplaySearch reports and more at www.displaysearch.com.

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August 10, 2012 — The polyvinyl alcohol (PVA) protection film industry will change significantly in 2012, with many display makers actively pursuing PVA-free and triacetate cellulose (TAC)-free designs. Display manufacturers are looking for costs savings, designs that suit tablet PCs and smartphones, and alternatives to Fuji Film, Displaybank reports.

Also read: Polarizer film trends

PVA films will grow to more than 800 million square meters (Msqm), based on area, in 2012, up from 740 Msqm in 2011. TAC film dominates the space, with 91% market share (about 750 Msqm) in 2012. COP will take 5% market share (40 Msqm), and acryl film is forecasted to have 3% of the market (240 Msqm).

By revenue, PVA protection film brought in Yen 331 billion in 2011, but will decline to Yen 326 billion this year, due to lower TN-use compensation film, the wide-view market, and competition between films. TAC film will bring in about Yen 300 billion.

Development efforts on new films are more active than ever in the history of LCD manufacturing. LCD makers are using polarizers with various combinations, looking for reduced film thickness.
Figure. Apple’s polarizer structures in different products. SOURCE: Displaybank.

Apple’s tablet PCs and smartphones have led the market with innovative structure and thickness. Companies are developing diverse films to supply polarizers to Apple, which has a big market with a single item, and technologies are rapidly moving from research to commercialization. For example, companies are using acryl film to make PVA films thinner. Acryl film has been applied as a compensation film of IPS-use polarizer, and could steal market share from conventional TAC. Processes to apply surface treatments to acryl are emerging as early as 2013, Displaybank reports.

Japan dominates the polarizer film industry. Giants of the polarizer industry, Nitto Denko, Sumitomo, and LG Chem, have their own acryl film production technology. Sumitomo Chemical and LG Chem can have higher price competitiveness than using the conventional TAC films as they secure the acryl resin production technology. 2012 will likely be the most important year for acryl’s offensive on TAC market share. TAC is clearly advantageous in production capacity, price, and know-how, Displaybank says, but acryl offers the display designs that smartphone and tablet makers want.

As these diverse technologies and films developed for mobile devices are applied to high-end TVs, future TV displays are expected to change greatly. If acryl films are used in TVs, the material will see rapid adoption from 2014.

Displaybank analyzed the polarizer film industry and various compensation films from 2010 to 2016 for the report “2012 Compensation Film and TAC/Acryl Film Analysis.” Access the report at http://www.displaybank.com/_eng/research/report_view.html?id=752&cate=4

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The FlexTech Alliance announced the Call for Papers is open for the 12th annual Flexible Electronics & Displays Conference & Exhibition. The 3 day multi-track Flex Conference consists of in-depth technical and business development presentations covering the entire flexible electronics supply chain. Taking place January 29 – February 1, 2013 in Phoenix, Arizona, the event also includes interactive exhibits and product demonstrations, a short course series, academic research, poster sessions and a variety of networking opportunities. The deadline for submission is September 22, 2012. 

The Flexible Electronics & Displays Conference & Exhibition attracts attendees from more than 10 countries and 200 companies, universities, R&D labs, and government agencies representing the many different segments of the flexible electronics and displays value and supply chains. Attendees span the roles of research, marketing, product development, manufacturing, senior business development, and executive functions.

The conference is a culmination of shared information, highlighting technical breakthroughs and demonstrating working products in flexible, printed electronics and displays. In addition to product demos and new applications, priority for paper selection will be given to original research and new toolset, process and materials introductions.

Topic areas sought are:

Business Strategies and Market Overviews for Flexible, Printed Electronics and Displays: Business Development; Road Mapping; Challenges to Early Adoption; and Customer Perspectives.

Flexible Electronics-Based Applications and Products: Flexible Displays; E-Book and Mobile Devices; Solar/Photovoltaics; Solid State Lighting and OLEDs; Energy Storage/Batteries; Smart Sensor Systems/RFID (biomedical, smart bandages, health monitors, smart clothing, neuro prosthetic devices, packaging, advertising/point of sales, pharmaceuticals, toys and entertainment, food monitoring, agricultural sensing, security, and structural monitoring).

Flexible Electronic Devices: Thin Film Transistors; Sensors and Detectors; Memory; Logic; Membranes; Device Design, Design Rules, Process Integration

Flexible Electronics Processes and Manufacturing: Additive Printing Processes (inkjet, gravure, flex, screen printing and other patterned deposition, print/ink optimization); Roll to Roll/Web Processing; Production Cost Reduction; Deposition Techniques and Equipment; Metrology; Flexible Electronics Production vs. Graphics Printing Production; Hybrid Manufacturing, Packaging, and Assembly; and Integration of printed electronics and microelectronics.

Flexible Electronics Materials: Substrates; Substrate Treatment to Optimize Films (conductors, insulators, semiconductors, light emitting; Functional Inks; Nanomaterials; Adhesives; Encapsulants; ITO Replacement; and Sustainable Materials.

Supply Chain Development

The conference, now in its 12th year, is moving to the Phoenix, Arizona Convention Center to accommodate its continuous growth. The new venue will provide technologically advanced amenities in a vibrant downtown location, while maintaining the superb networking atmosphere that has long characterized the Flex Conference. With the expanded exhibit space, attendees will be able to engage with more suppliers, customers and partners in flexible, printed electronics R&D, design and manufacturing.  

For more information or to download the Call for Papers for the 2013 Flex Conference, visit www.flexconference.org. Online submissions are now available.  

August 9, 2012 — Active-matrix organic light-emitting diode (AMOLED) displays are growing rapidly and offer many performance benefits over liquid crystal displays (LCDs). However, 55” AMOLED TV displays cost 8-10x as much as a comparable LCD to manufacture.

Also read: AMOLED manufacturing improvements to enable TV market share grab

According to the NPD DisplaySearch AMOLED Process Roadmap Report, the manufacturing cost of a 55” oxide TFT-based AMOLED using white OLED (WOLED) with color filters is 8x that of a high-end TFT LCD display of equal size. The cost multiplier of a 55” AMOLED module using red, green, and blue (RGB) OLED is 10x. These higher costs are mainly a result of low yields and high materials costs.

LCD manufacturing is a mature process with slower, more incremental cost reduction. AMOLED cost reduction efforts are in their infancy, said Jae-Hak Choi, senior analyst, FPD Manufacturing for NPD DisplaySearch. These could include new and improved processes, printing technology, and higher-performance materials that will take AMOLED prices to parity with LCD in the long term.

Figure. Relative manufacturing costs of technologies for 55” TV panels. Based on current yield and material cost assumptions. Source: NPD DisplaySearch AMOLED Process Roadmap Report.

In order to scale up to large sizes, advancements in several aspects of AMOLED manufacturing are needed, including the active matrix backplane, organic material deposition, and encapsulation. Because oxide thin-film transistors (OTFT) require lower capital costs and are similar to existing amorphous silicon TFT (a-Si TFT), the technology offers a strong alternative to the low-temperature polysilicon (LTPS) TFT currently used for AMOLED. However, there are many hurdles for mass production of oxide TFT, particularly threshold voltage shifts, which are continuing to prove problematic for AMOLED production.

While indium gallium zinc oxide (IGZO) and other forms of oxide TFT show great promise for backplanes, progress in scaling up LTPS production is also being made by increasing the excimer laser beam width to 1300 mm. In addition, the current method of depositing red, green, and blue materials by evaporation through a fine metal mask is being continuously improved. Pixel densities of 250 ppi are now possible, and over 280 ppi is feasible.

“High resolution patterning such as laser induced thermal imaging (LITI) and material improvements are still required for AMOLED to be highly competitive for super-high-resolution flat panel displays,” Choi said.

Manufacturing processes for small, 4” AMOLED displays are more mature, creating a much smaller cost premium over LCDs (<1.3x). Most AMOLED capacity is currently dedicated to small/medium production for smart phones, but much of the future capacity increase will be driven by fabs dedicated to TV production. Uncertainties abound, as AMOLED technology has not yet been proven in large-size TVs.

Based on planned investments, NPD DisplaySearch forecasts that the AMOLED market will grow nearly tenfold from 2.3M square meters in 2012 to more than 22M in 2016.

Samsung Display has been highly successful in its small/medium AMOLED production because it has been able to raise yields to near-LCD levels. This implies that manufacturers can potentially lower large-size AMOLED TV costs to be competitive with LCD TVs in the future.

The NPD DisplaySearch AMOLED Process Roadmap Report provides in-depth data and analysis on OLED manufacturing technologies including materials, backplanes, OLED, and encapsulation. It also includes an analysis of benefits, opportunities, negatives, and challenges for each technology. Unique to the industry, the report shows specification roadmaps for OLED manufacturing through 2016 and indicates which manufacturing technologies will be required to achieve stability and performance. Also, the report provides a unique equipment investment simulation and module cost modeling analysis. NPD DisplaySearch provides market research and consulting, specializing in the display supply chain, as well as the emerging photovoltaic/solar cell industries. For more information on DisplaySearch analysts, reports and industry events, visit http://www.displaysearch.com/.

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August 9, 2012 — AIXTRON launched the PRODOS-200 PVPD system for deposition of organic thin film materials, used to make organic thin-film transistor (OTFT) displays, organic light-emitting diodes (OLEDs) and other manufacturing applications.

The system supports research on new deposition processes for polymer thin films and easy transfer to industrial processes with high deposition rates, high contour conformity of the deposited layers, and unrestricted scalability based on AIXTRON’s Close Coupled Showerhead technology.

AIXTRON expects adopters to develop new conductive and flexible layers, manipulate surface properties, and create flexible barrier layers, as well as improving today’s deposition processes and structures. The PRODOS line is designed to be modular and expandable for source materials in liquid, gaseous, or solid forms. It supports various PVPD processes, or all-dry processes, in which the carrier gas-based, gas phase deposition is used for the in-situ polymerization and layer formation of functional polymer thin films.

The tools accommodate substrates up to 200mm2. They can be integrated into cluster environments by means of relevant SEMI-compatible interfaces and are compatible with other AIXTRON systems, such as the OVPD* R&D line. The double-wall-chamber construction makes the system eases maintenance and enables fast modifications.

AIXTRON also recently announced that its BM II (2-inch) system is being used for research on depositing carbon nanotube (CNT) arrays for 3D devices, such as nano-antennas and nano-rectifiers by Daegu Gyeongbuk Institute of Science & Technology (DGIST) in South Korea.

*OVPD technology has been exclusively licensed to AIXTRON from Universal Display Corporation (UDC) for equipment manufacture. OVPD technology is based on an invention by Professor Stephen R. Forrest et al. at Princeton University, which was exclusively licensed to UDC. AIXTRON and UDC have jointly developed and qualified OVPD pre-production equipment.

AIXTRON provides MOCVD production technologies for semiconductor devices, such as LEDs, lasers, transistors and solar cells. For further information on AIXTRON (FSE: AIXA, ISIN DE000A0WMPJ6, DE000A1MMEF7; NASDAQ: AIXG, ISIN US0096061041), see www.aixtron.com.

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August 7, 2012 — Brown University developed a simpler, cheaper, solution-based manufacturing process for indium tin oxide (ITO) conductive films used in displays and solar cell manufacturing.

Brown researchers, with support from ATMI Inc., reported the best-ever transparency and conductivity performance for an ITO made using a chemical solution.

  

Figure. Electron microscopy (cross-section, left, and facing view) shows an even distribution of indium titanium oxide nanocrystals essential for a highly conductive, transparent thin film. Credit: Sun Lab/Brown University.

The ITO offers high enough performance for applications in resistive touch screens, said Jonghun Lee, a Brown chemistry graduate student. The films allow 93% of light to pass through, deposited at 146nm thick. Their transparency is comparable to the glass substrate.

The team also made their films on top of bendable polyimide, showing that it could potentially be useful for making flexible display technologies.

To make the films, the team synthesized nanoscale ITO crystals in a solution. Then they made a flat and smooth film by spin casting the solution on a glass plate. Coated plates were then annealed for several hours (ideal anneal time was 6 hours) and then tested their transparency and conductivity.

The materials research was key to enable the simple spin-casting assembly method, said Shouheng Sun, professor of chemistry at Brown. The best chemicals turned out to be indium acetylacetonate and tin bis(acetylacetonate)dichloride. Researchers synthesized ITO nanocrystals that had a narrow range of sizes, about 11nm in diameter. That consistency meant that when the crystals arranged themselves in the thin films, they neither bunched together in clumps, nor stayed too far apart. The result was a dense but evenly distributed array of crystals, which promotes conductivity.

By varying the thickness and the tin content (between 5 and 10%), researchers varied the transparency and resistance for the best results. The key to a smooth, consistent film was the uniform size of ITO nanocrystals. The researchers settled on a diameter of around 11nm. “By controlling the concentration of the nanocrystal solution, we could control the thickness of the film from 30 to 140nm,” Lee said.

The team will now work on matching the conductivity performance of films made by sputtering, while maintaining the cost and process efficiency benefits of solution-based deposition, according to Melissa Petruska, senior scientist at ATMI.

In new experiments, the team plans to further drive down electrical resistance, to reduce the length of time the films need to anneal, and to lay down fine patterns of their films, rather than continuous sheets, using inkjet or roll-to-roll printing.

Results are published in a paper posted online Aug. 1 by the Journal of the American Chemical Society. In addition to Sun and Lee, the other Brown authors are Sunghwan Lee, Guanglai Li and David Paine. Petruska is a co-author on the paper. ATMI provided project funding and engineering assistance for the research.

Learn more at www.brown.edu.

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August 7, 2012 — Apple’s new iPad uses a 9.7” QXGA display, which is difficult to manufacture with existing thin-film transistor liquid-crystal display (TFT-LCD) processes, due to the high resolution and strict quality requirements. This may be causing Apple to adjust its display panel supplier mix or cut back production, according to a blog by David Hsieh, VP, Greater China market of DisplaySearch.

Hsieh reports that speculation is revolving around Apple’s production volumes for iPad panels, which he says is “likely a case of Apple and its suppliers trying to gain leverage on each other.”

Various theories have been floated as for why Apple would reduce iPad display panel production: increased Foxconn inventories, unsatisfactory cost-reduction plans at panel and component suppliers, saturation in the market, panel supplier mix changes due to the challenging manufacturing requirements, and potential new iPad models like the “mini.”

Hsieh suggests that — if Apple is actually cutting production — some capacity dedicated to iPad panel production would be released, increasing oversupply.

Some panel makers, like LG Display and Sharp are using advanced Gen-8 LCD fabs to produce tablet PC panels, DisplaySearch reports, and some are ramping up oxide TFT (OTFT) technology for iPad panel production. The high resolution and quality requirements for the new iPad panel, as well as the mix of TFT technologies being used (a-Si and oxide) could make Apple adjust the mix of panel suppliers. Apple’s preference is to use oxide in the panels for the new iPad, as this technology enables the use of smaller transistors in each pixel, allowing more light from the backlight to pass through. This allows for higher battery life or brightness, Hsieh said. Challenges in producing OTFT have limited its use. The degree to which those challenges can be mitigated in the short term may affect not only how widely oxide is used but also the bill of materials cost.

Other considerations, like panel prices, are covered in Hseih’s blog post, “Mixed Signals On iPad Panel Production,” at http://www.displaysearchblog.com/2012/07/mixed-signals-on-ipad-panel-production/.

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August 7, 2012 — Organic light-emitting diodes (OLEDs) are making inroads into displays, particularly small- to medium-sized units, and lighting. With OLED adoption, the total market value of materials used in OLED applications will grow quickly from about $500 million in 2012 to over $7 billion by the end of 2019, reports NanoMarkets.

Active OLED materials — emissive materials, hosts, and hole/electron injection and transport materials — will account for nearly $3 billion of that $7 billion pool.

Also read: OLED adoption means shifting reqs for OLED materials

NanoMarkets’ research report, “OLED Materials Markets 2012,” provides analysis and forecasts for OLED materials in the coming 8 years. It examines some of the latest market strategies, products and technical developments in OLED materials, as well as identifies how performance improvements are growing some addressable markets for OLEDs. Assessments of strategies at several top OLED materials suppliers are also included. Furthermore, the study is supplemented with granular eight-year forecasts of materials shipments in both OLED panel area and value terms, with breakouts by material type, deposition technology, and by panel type.

Material categories covered include: functional OLED materials in the emissive layer and hole/electron transport/injection/blocking layers as well as substrates, electrodes, and encapsulation technologies.

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August 6, 2012 — The global market for public displays is strong, but in recent quarters, flat panel display (FPD) manufacturers have emphasized revenue and profit over volume, thus lowering the overall unit shipment outlook for this category. As production of plasma displays winds down, LCD-based commercial displays have yet to fully fill the void. With reduced production of plasma, the public display market fell 13% year over year (Y/Y). However, LCD public display shipments were up 23% Y/Y, according to the NPD DisplaySearch Quarterly FPD Public Display Shipment and Forecast Report.

Forecasts still show strong growth, with the market set to push near 12 million units sold in 2018, an increase from just under 3 million units in 2011. Growth will be driven by new applications for public displays such as digital signage, interactive white boards, video walls, electronic menu boards, as well as the global trend toward urbanization in developing countries seen most visibly in China.

Figure 1. Worldwide LCD commercial public display shipments and forecast. SOURCE: NPD DisplaySearch Quarterly FPD Public Display Shipment and Forecast Report.

The advantage that plasma once had over LCD—larger displays for less money—has been disappearing over the years. Today, vendors such as Sharp are able to produce 60” and larger LCDs at less cost. Plasma had been able to capture some of the lower-end demand for public displays with that demand also being fulfilled by lower-priced consumer-TV displays. Leading vendors of commercial public displays, such as Samsung and NEC, are now focusing on 40” and larger sizes, conceding that the demand for medium-sized (26” to 39”) digital signage can be fulfilled by TV-grade products

In recent years, LCD manufacturers have been better able to differentiate their larger size displays (40” and larger) from similarly-sized consumer TV products with technologies such as thinner bezels, which allow for better video wall installations. Backlight technologies, such as LED, also offer unique solutions, allowing for not only thin displays, but also for higher brightness, which is needed by many commercial applications to perform in various ambient light conditions.

“This focus on higher-margin, larger-size displays is welcoming news—not just for display brands but for their global integrators alike. With a focus on technologies that have relevance to specific end-market needs, other players in the digital signage ecosystem also benefit by avoiding price comparisons against commoditized TVs,” noted Chris Connery, NPD DisplaySearch VP of PC and large-format commercial displays.

While the use of TVs in commercial environments is not always apparent, NPD DisplaySearch’s sell-through research with top commercial distributors and resellers indicates vendors that offer hybrid products that are a mix of commercial displays and consumer TVs. Detailed US commercial sell-through data shows that hybrid displays grew 85% Y/Y in Q1’12, outpacing pure commercial displays at only 5% Y/Y.

Connery added, “While the total market size for public displays is not shrinking, more displays now fall into different categories, which can be documented in new ways, such as when consumer TVs are used for commercial applications.”

Figure 2. US distributor & reseller sell-through of large-format commercial (26”+) LCDs by category. SOURCE: NPD DisplaySearch Monthly Large Format Commercial Displays Sell Through Report.

 

The NPD DisplaySearch Quarterly FPD Public Display Shipment and Forecast Report analyzes historical shipments, revenues, and forecast projections to provide an accurate, detailed view of the public display market. NPD DisplaySearch has been recognized as a leading global market research and consulting firm specializing in the display supply chain, as well as the emerging photovoltaic/solar cell industries. For more information on DisplaySearch analysts, reports, and industry events, visit http://www.displaysearch.com/.

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