Emitting arrays providing off-axis color correction for video wall displays

Abstract

The disclosed embodiments provide an emissive array of color pixels where adjacent pixels are positioned relative to one another, such as by using different color orders, orientations, or arrangements. As a result, when a large group of emitters are viewed simultaneously from a particular viewing angle, off-axis color distortion is more distributed among many viewing angles and reduced or even eliminated. This is one common viewing behavior for both human viewers and image capture devices for video display walls. The embodiments may be formed as surface mounted devices (SMDs).

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 270,553, entitled “Surface Mount Apparatus Providing Off-Axis Color Correction for Dynamic Image Capture of Video Wall Displays,” filed October 21, 2022, and which is hereby incorporated by reference in its entirety.

[0002] The present disclosure generally relates to the field of LED display devices. In particular, the present disclosure is directed to a light emitting array that provides off-axis color correction for video wall displays, and more specifically, in some embodiments, the light emitting array may be configured as a surface mounted device (SMD). [Background technology]

[0003] Video walls, consisting of an array of LED display tiles and displaying moving images, are increasingly being used as backgrounds for movie sets and broadcast video scenes. As an example, in a movie set, instead of performing in front of a green screen with a background that is later added by CGI technology, actors perform in front of a video wall that dynamically displays a desired background scene, which is then captured by a camera along with the actors. In another example, in broadcast video, in a news broadcast, a presenter is positioned in front of a video wall, and a video camera captures both the presenter and an image displayed on the video wall behind the presenter. With this technique, the camera capturing the scene is not only capturing the live action or performance in front of the video wall, but also the image simultaneously displayed on the video wall behind the live action. Thus, the display on the video wall is a moving, variable part of the scene captured by the camera. Because the video camera is actually capturing the scene displayed on the video display wall, there are several challenges to overcome in order for the image captured by the video camera not to appear with artifacts or other distortions that would adversely affect the quality of the captured image.

[0004] One problem to overcome is color distortion or variation that occurs when a camera captures an image produced by an array of LED pixels at various viewing angles. LED tiles have different color performance when viewed off-axis from the vertical. This is due to the diode arrangement as well as the physical properties of the pixel structure. Some pixels may have RGB subpixel color components arranged in a vertical line, while others may be arranged in a triangle. The internal arrangement of subpixel color components varies from manufacturer to manufacturer due to electronic or manufacturing constraints, especially as components become increasingly smaller. In addition to the non-uniformity of a single pixel, when multiple LEDs are arranged on a circuit board to make a display panel, the physical structure of adjacent pixels may shield each other, preventing certain portions of the pixel from being fully visible. All of these variations result in different appearances at different viewing angles. The variations can be minor to dramatic, as shown in FIG. 16 (color image at time of filing), depending on the viewing angle.

[0005] The lack of uniformity of the display when viewed from different angles can be very unappealing for a plain white field that must remain the "same" color or shade regardless of viewing angle, or for important content such as a corporate logo. The amount of variation from a standard or desired color (in this case a blank screen presenting a D65 illuminant) can vary based on the amount of variation from the vertical viewing angle (position 2). Note that FIG. 16 presents a simplified depiction in that the only variation shown between positions 1, 2, and 3 is along the horizontal axis. The same type of color variation occurs equally when the viewing angle is shifted vertically above or below the display centerline. The details shown for positions 1, 2, and 3 also represent the field of view across a fixed field of view at each position. In these simplified printed diagrams, the variation may not appear large, but in reality, when the display wall shows images with complex color variations and motion, the color distortion can be very dramatic at certain viewing angles, depending on the physical configuration of the LED tiles and video wall.

[0006] A contributing factor to the color distortion mentioned above is the presence of small patterns inside the emitters themselves. These internal patterns are created by internal components of the emitters such as bonding pads and electrodes. As a result, if the distribution of light from the emitters is not perfectly uniform, it will be distorted off-axis. Another technical challenge in trying to address color distortion is the fact that in current high resolution screens, routing the PCB is extremely difficult and time consuming. This is a major technical barrier to alternative emitter arrangements that can reduce off-axis color distortion. For example, current high resolution screens typically have emitters that are arranged in a very regular grid and repeating pattern. Most commonly found is a uniform row of red emitters, followed by a uniform row of green emitters, then a uniform row of blue emitters. This pattern is typically repeated across the entire display surface. Changing this regular repeating arrangement with conventional manufacturing techniques would add significant technical challenges, complexity and cost to the PCB in order to make the appropriate connections to driver chips, power rails, etc. Summary of the Invention [Problem to be solved by the invention]

[0007] One possible solution for correcting such off-axis color distortion in captured images is described in Applicant's co-pending PCT Application No. PCT / US21 / 56123, entitled "Off-Axis Color Correction in Video Capture for Video Wall Displays," filed October 21, 2021, which is incorporated herein by reference. The solution described in this incorporated pending application involves applying a software-implemented color correction layer to the camera viewing area on the display surface to reduce or eliminate color distortion in the displayed image.

[0008] Another solution is provided in this disclosure in the form of an SMD device that is configured to avoid or minimize the need for color correction during image capture. The solution of the present invention also addresses and resolves technical challenges that arise in conventional devices from the use of light emitters arranged in a non-linear row pattern. [Means for solving the problem]

[0009] In one implementation, the present disclosure is directed to a light emitting device that includes an array of self-emitting pixels, where each pixel of the array comprises the same multiple different color light emitters, where the different color light emitters of each pixel of the array are arranged in at least one of a different order, a different orientation, or a different arrangement relative to the different color light emitters in at least two adjacent pixels of the array.

[0010] In another embodiment, the present disclosure is directed to a light emitting device configured as a surface mounted device that reduces off-axis color distortion from a particular viewing angle, the device including a 2×2 pixel microarray, where one row is made up of a first pixel formed from a sequence of red, green, and blue LEDs and a second pixel formed from a single white LED, and another row is made up of a first pixel formed from a sequence of blue, green, and red LEDs.

[0011] In yet another embodiment, the present disclosure is directed to a light emitting array providing off-axis color correction for a video wall display, the light emitting array including an SMD having at least four pixel groups arranged in a 2×2 array, where vertically adjacent pixel groups and horizontally adjacent pixel groups include a plurality of individual light emitters positioned differently relative to one another, whereby off-axis color distortion of the individual light emitters is distributed among a plurality of viewing angles to reduce or eliminate cumulative off-axis color distortion of the light emitting display.

[0012] In yet another embodiment, the present disclosure is directed to a method of making a light emitting device. The method comprises configuring a plurality of multicolor pixels in two different pixel arrangements and surface mounting the multicolor pixels of a microarray to a microarray substrate. Each multicolor pixel comprises a plurality of different color light emitters. Each of the different pixel arrangements differs from the other pixel arrangements by at least one of light emitter color order, color emitter orientation, or color emitter placement, and has an overall height and an overall width. Each multicolor pixel has a pixel arrangement that differs from its horizontally adjacent and vertically adjacent multicolor pixels. [Brief description of the drawings]

[0013] For the purpose of illustrating the present disclosure, the drawings show aspects of one or more embodiments of the present disclosure, it being understood, however, that the present disclosure is not limited to the precise arrangements and instrumentalities shown in the drawings.

[0014] [Figure 1] FIG. 1 is a schematic diagram of a first embodiment of an LED microarray according to the present disclosure. [Diagram 2] FIG. 2 is a schematic diagram of a second embodiment of an LED microarray according to the present disclosure. [Diagram 3] FIG. 13 is a schematic diagram of a third embodiment of an LED microarray according to the present disclosure. [Figure 4] FIG. 13 is a schematic diagram of a fourth embodiment of an LED microarray according to the present disclosure. [Diagram 5] FIG. 2 is a schematic diagram of a portion of an LED display tile utilizing the microarray embodiment shown in FIG. 1. [Figure 6] FIG. 13 is a schematic diagram of a fifth embodiment of an LED microarray according to the present disclosure. [Figure 7] FIG. 13 is a schematic diagram of a sixth embodiment of an LED microarray according to the present disclosure. [Figure 8] FIG. 7 is a schematic diagram of a portion of an LED display tile utilizing an embodiment of a microarray as shown in FIG. 6. [Figure 9] FIG. 2 is a partial schematic plan view of an LED tile according to an embodiment of the present disclosure. [Figure 10] FIG. 1 is a schematic plan view of a microarray according to an embodiment of the present disclosure. [Figure 11] 1 is a schematic cross-sectional view of a microarray according to an embodiment of the present disclosure. [Figure 12] FIG. 2 is a schematic cross-sectional view of a microarray according to another embodiment of the present disclosure. [Figure 13] FIG. 1 illustrates average adult visual acuity as applied to embodiments of the present disclosure. [Figure 14] FIG. 2 is a front view of an LED display according to the present disclosure utilizing tiles made from microarrays as disclosed herein. [Figure 15] FIG. 1 is a partial schematic plan view of an example of a conventional LED tile. [Figure 16] 1 shows a simplified example of color distortion that can result from off-axis viewing of an LED video wall. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] The embodiments disclosed herein provide an off-axis color correction solution to the above-mentioned problems using a surface mounted device (SMD) comprised of a microarray of alternating RGB(N) (red / green / blue / (other possible color) or RGB(N)+W (red / green / blue / (other possible color)+white) pixels, as well as other SMD features and advantages as described below. The disclosed embodiments utilize a microarray of light emitters, where the light emitters are arranged in a pattern that minimizes or eliminates off-axis color distortion when an image shown on a display wall comprised of tiles comprised of the microarray is captured at various angles using an image capture device. Details of various embodiments of the individual microarrays 102A-F are shown in FIGS. 1-4, 6 and 7. Note that in the following description, reference numeral 102 is used to collectively refer to all of the microarrays 102A-F with respect to features or configurations common to all of the embodiments.

[0016] As shown in FIG. 1, the microarray substrate 104 has 12 LEDs mounted thereon. The 12 LEDs form four pixels. In other words, the 12 LEDs form a 2×2 pixel array that constitutes a single microarray 102A. In this example, each pixel includes one red LED 110, one green LED 112, and one blue LED 114. However, the pixels are formed with different colored LEDs arranged in a different order as shown to provide more uniform color characteristics from a wide range of image capture / viewing angles. FIGS. 2, 3, and 4 show alternative embodiments in which microarrays 102B, 102C, and 102D are fabricated substantially as microarray 102A, but have different arrangements of different colored LEDs 110, 112, and 114 such that the light emitters are positioned in multiple angular orientations relative to one another across the display surface to distribute the non-uniform color characteristics in a less perceptible pattern. For example, a different orientation is shown in FIG. 2, a different arrangement is shown in FIG. 3, and a different order is shown in FIG. 4.

[0017] As mentioned above, in conventional LED-based display devices, internal components result in non-uniform distribution of light emission that causes off-axis color distortion. Not only is there color distortion because of this, but the color distortion may be different for each of the red, green, and blue light emitters, further complicating potential solutions. Thus, in embodiments of the present disclosure, the fact of off-axis color distortion per emitter is accepted, and no attempt is made to individually create perfectly uniform emitters. Instead, the present disclosure arranges adjacent pixel groups relative to each other, such as by using different color orders, color orientations, or color arrangements, such that when a large group of emitters is viewed simultaneously from a specific viewing angle (as is the typical viewing modality for both human viewers and image capture devices), the off-axis color distortion is more distributed among many viewing angles and reduced or even eliminated. Increasing the number of individual emitters at different relative angles to one another further reduces off-axis color distortion, but it has been determined that the relative rotation of just two or four of the emitters, or small groups of emitters, is sufficient to "blend" the distortion of the individual emitters and achieve improved results in the form of reduced or eliminated color distortion. For example, by flapping the RGB / BGR in a checkerboard pattern, the arrangement can provide a pleasing horizontal and vertical appearance with a pinwheel arrangement on top of which the emitters are further rotated and flapped 90 degrees, achieving excellent results in terms of color distortion or elimination of distortion at off-axis viewing angles.

[0018] Referring again to FIG. 1, the relative positions of the pixels or groups of pixels to one another can be described. In the embodiment shown in FIG. 1, each pixel or group of pixels is identified by a dashed box labeled 121, 122, 123, and 124. Each pixel or group of pixels is composed of red, green, and blue LEDs 110, 112, and 114, respectively, arranged in a different order. As shown in the figure, pixel group 123 has horizontally adjacent pixels 122, vertically adjacent pixels 124, and diagonally adjacent pixels 121 as neighboring pixel groups. In various alternative embodiments disclosed herein, an array of pixels has pixels (or a single white pixel) arranged in this same manner. Thus, the meanings of the terms horizontally adjacent, vertically adjacent, and diagonally adjacent, as defined in this paragraph, are used throughout.

[0019] In some embodiments, each LED 110, 112, 114 is directly bonded to the substrate 104. Pre-packaging the microarray 102 into a single package as disclosed herein provides additional advantages in manufacturing by reducing pick-and-place time and simplifying complex printed circuit board (PCB) design to achieve complex pixel arrangements, but with a standard formatted microarray that can be uniformly positioned and connected.

[0020] FIG. 5 illustrates a portion of a tile 106A according to one embodiment of the present disclosure. The tile 106A comprises an array of microarrays 102 mounted on a suitable primary tile substrate 108. The primary tile substrate 108 may be, for example, a printed circuit board (PCB) or other suitable substrate. Examples of substrates suitable for the primary tile substrate 108 include standard PCB materials such as FR4, flexible circuit materials or foils, conductive fabrics, conductive glass, or metal circuit boards. The tile 106A may extend in the X and Y directions as needed to form the desired tile dimensions for a particular application. For example, the tile dimensions may include a 10×10 array of microarrays 102, or a 100×100 array, or any array in between, smaller, or larger. It is noted that for microarrays 102 located at the edge of a larger tile array, the spacing to the edge of the tile substrate 108 is half the spacing between adjacent microarrays 102 to provide a visually continuous appearance when multiple tiles 106A are adjacent to form a video panel.

[0021] In a further alternative embodiment, as shown in Figures 6 and 7, the microarray substrate 104 carries thereon eight LEDs forming four pixels. In other words, the microarray substrate 104 forms a 2x2 pixel array that constitutes a single microarray 102E or 102F. In these examples, two pixels include one each of a red LED 110, a green LED 112, and a blue LED 114. Also, two pixels include a single white LED 116. As in the above-mentioned embodiment, the microarrays 102E and 102F are formed with differently colored pixels arranged in different orders, as shown in Figures 6 and 7, to provide more uniform color characteristics from a wide range of image capture / viewing angles. Figures 6 and 7 show an alternative embodiment in which the microarrays 102E and 102F are fabricated in a substantially similar manner, but different orientations of the differently colored LEDs 110, 112, and 114 are again arranged in flapped and rotated orientations as described above.

[0022] With respect to the embodiment shown in Figures 6 and 7, each LED 110, 112, 114 and 116 may be directly bonded to the substrate 104. In another embodiment, the RGB LEDs 110, 112 and 114 are directly bonded to the substrate 104, while the W LED 116 is formed on a separate substrate and then bonded to the substrate 104. For example, the W LED 116 may itself be formed as an SMD package with a small blue emitter (die) for exciting an illumination substance such as a phosphor that covers all or substantially all of a designated area of ​​the W LED 116 to provide a white illumination area of ​​suitable dimensions as described below. In yet another embodiment, the RGB LEDs 110, 112 and 114 are themselves surface mounted on a separate substrate and then bonded to the substrate 104. The separate substrate may include a standard PCB itself made from FR4 material or the like, or may be a wafer substrate material such as sapphire, silicon, silicon carbide or gallium nitride. As is generally known in the art, the substrates described herein may include multiple layers including, for example, ceramic layers, metal interconnect layers, and underlayers that include elements such as thermal pads and cathodes.

[0023] In another advantage of the embodiments disclosed herein, the microarrays 102 may be individually encapsulated with a light-transmitting encapsulation layer that covers the LEDs. Examples of encapsulation layer materials include silicone or epoxy resin / potting compounds, or conformal coatings such as parylene, paraxylene, acrylic, silicone, polyurethane, or lacquer. Additionally, lenses, such as epoxy or silicone lenses, may be optionally placed over the entire microarray or over individual or groups of light emitters.

[0024] The embodiments described herein are readily adapted to different types of surface mount packaging as may be best suited for a particular application. For example, the embodiments disclosed herein may be provided in various types of flat no-lead packages, such as ball grid array (BGA) packages, quad flat no-lead (QFN) packages, or various chip carrier packages, such as plastic lead chip carrier (PLCC) packages.

[0025] One feature of the embodiments disclosed herein is that the dimensions of the white LED 116, i.e., the overall outline (height and width) dimensions, are at least substantially the same as the combined dimensions (combined height and width) of the RGB LEDs 110, 112, and 114, so as to provide a smooth and consistent visual appearance in all lighting conditions. This means that in various embodiments the combined height and width of the multicolor pixel and the height and width of the white pixel, if not identical, differ from each other by about 1% to about 20% (within ±0% dimensionally identical). (Within ±0% dimensionally identical.) In some embodiments, the combined height and width of the multicolor pixel is about 5% to about 10% of the height and width of the white pixel.

[0026] The spacing and dimensions of the microarray 102 can be based on the visual acuity of the viewer. Typical visual acuity for an adult is a dimension of one arc minute, or approximately two pixels per degree. In general, the dimensions of the microarray should be selected such that the viewer does not perceive the boundaries of the microarray. Parameters to consider when determining the dimensions of the microarray 102 include an array dimension that is large enough to provide improved durability and robustness, yet small enough for repairability to the array on the PCB.

[0027] The distance between the viewer and the display has a direct correlation with the ideal array dimensions, but typically the pixel pitch is also selected based on this distance. In one example, a 100x100 pixel array can be formed in accordance with the present disclosure using an array of microarrays 102 with partial pixels and pixels as small as a 2x2 array and as large as a 16x16 array. As a result, the microarray dimensions do not need to exceed 5mmx5mm. For a 2x2 microarray, the SMD footprint is four times larger than a single RGB SMD pixel, but still small enough that it can be replaced to repair the array without becoming commercially unreasonable. It is also small enough that it is within the line of sight to the extent that the viewer cannot see the physical pattern or division of a very large array (in other words, the "texture" of the front of a very large display appears uniform).

[0028] In one example, the dimensions of the microarray 102 may be approximately 5 mm by 5 mm or less. In a 5 by 5 mm microarray, the individual pixel dimensions may be in the range of approximately 2 by 2 mm to approximately 2.4 by 2.4 mm in some embodiments. As an illustrative example, the white LEDs 116 may comprise 6504 Kelvin or 2700 Kelvin LEDs. A further feature of the embodiments disclosed herein is that each microarray 102 may be individually encapsulated. Thus, if an LED fails on one microarray, only that particular microarray needs to be replaced. The replaced microarray provides a more uniform appearance to the existing microarrays since any variations in the encapsulation layer are within each of the microarrays. Also, if a single LED fails, only a single microarray, e.g., just eight LEDs in one embodiment, is required to be replaced, resulting in much greater efficiency and less waste compared to conventional designs.

[0029] FIG. 8 illustrates a portion of a tile 106B according to one embodiment of the present disclosure. The tile 106B comprises an array of microarrays 102E mounted on a suitable primary tile substrate 108, which may be, for example, a printed circuit board (PCB) or other suitable substrate. Examples of substrates suitable for the primary tile substrate 108 include standard PCB materials such as FR4, flexible circuit materials or foils, conductive fabrics, conductive glass, or metal circuit boards. The tile 106B may extend in the X and Y directions as needed to form the desired tile dimensions for a particular application. For example, the tile dimensions may include a 10×10 array of microarrays 102, or a 100×100 array, or any dimension in between, smaller, or larger. Note that for a microarray 102E positioned at the edge of a larger tile array 106B, the spacing to the edge of the tile substrate 108 will be half the spacing of adjacent microarrays 102E so as to provide a visually continuous appearance when multiple tiles abut to form a video panel.

[0030] 9-14 illustrate additional SMD-related features that may be incorporated into a light emitting device that provides off-axis color correction in a video display. For example, FIG. 9 illustrates a portion of a tile 200 according to one embodiment of the present disclosure. The portion of the tile 200 comprises an array of microarrays 202 mounted on a suitable primary tile substrate 204. A suitable primary tile substrate 204 may be, for example, a printed circuit board (PCB) or other suitable substrate. Examples of substrates suitable for the primary tile substrate 204 include standard PCB materials such as FR4, flexible circuit materials or foils, conductive fabrics, conductive glass, or metal circuit boards. As indicated by arrows X and Y along the edge of the tile substrate 204, the tile 200 may extend in each X, Y direction as needed to form the desired tile dimensions for a particular application. For example, the tile dimensions may include a 10×10 array of microarrays 202, or a 100×100 array, or any dimension in between, smaller, or larger. For microarrays 202 located on the edge of a larger tile array 200, the spacing to the edge of the tile substrate 204 is half the spacing of adjacent microarrays 202, providing a visually continuous appearance when multiple tiles 200 are abutted to form a video panel. Further spacing considerations are discussed below.

[0031] Detailed embodiments of an individual SMD microarray 202 are shown in Figures 10, 11, and 12. As shown in Figure 10, a microarray substrate 206 has eight LEDs thereon that form four pixels, or in other words, eight LEDs that form a 2x2 pixel array that makes up a single microarray 202. In this example, two pixels include one red LED 210, one green LED 212, and one blue LED 214, and two pixels include a single white LED 216. In one embodiment, each LED 210, 212, 214, and 216 are bonded directly to the substrate 206, as shown in Figure 11. In another embodiment, the RGB LEDs 210, 212, and 214 are bonded directly to the substrate 206, while the W LED 216 is formed on a separate substrate 220 and then bonded to the substrate 206, as shown in Figure 12. For example, the W LED 216 may itself be formed as an SMD package with a small blue emitter (die) for exciting an illumination substance such as a phosphor, which covers the entire or substantially entire designated area of ​​the LED 216 to provide a white illumination area of ​​suitable dimensions, as described below. In yet another embodiment, the RGB LEDs 210, 212 and 214 are themselves surface mounted on separate substrates and then bonded to the substrate 206. The substrate 206 may comprise a standard PCB itself made from FR4 material or the like, or may be a wafer substrate material such as sapphire, silicon, silicon carbide, or gallium nitride. As is commonly known in the art, the substrate 206 may comprise multiple layers, including, for example, a ceramic layer 222, a metal interconnect layer 224, and an underlayer 226 including elements such as a thermal pad and a cathode.

[0032] In another advantage of the embodiments disclosed herein, the microarrays may be individually encapsulated with a light-transmissive protective encapsulation layer 228 that covers the LEDs, as shown in FIG. 11. Examples of materials for the encapsulation layer 228 include silicone or epoxy resin / potting compounds, or conformal coatings such as parylene, paraxylene, acrylic, silicone, polyurethane, or lacquer. Additionally, a lens 230, such as an epoxy lens or a silicone lens, may be optionally placed over the entire microarray or over individual or groups of light emitters, as shown in FIG. 12. In some embodiments, the encapsulation layer 228 may be used in conjunction with the lens 230.

[0033] The embodiments described herein are readily adapted to different types of surface mount packaging as may be best suited for a particular application. For example, the embodiments disclosed herein may be provided in various types of flat no-lead packages, such as ball grid array (BGA) packages, quad flat no-lead (QFN) packages, or various chip carrier packages, such as plastic lead chip carrier (PLCC) packages.

[0034] One feature of the embodiments disclosed herein is that the dimensions, i.e., overall outline (height and width) dimensions, of the white LED 216 are at least substantially the same as the combined dimensions (combined height and width) of the RGB LEDs 210, 212, and 214 to provide a smooth and consistent visual appearance in all lighting conditions. This means that in various embodiments, the combined height and width of the multicolor pixel and the height and width of the white pixel, if not identical, differ from each other by about 1% to about 20% (within ±0% the dimensions are identical). In some embodiments, the combined height and width of the multicolor pixel are about 5% to about 10% of the height and width of the white pixel.

[0035] The spacing and dimensions of the microarray 202 can be based on the visual acuity of the viewer. Typical visual acuity of an adult is a dimension of one arc minute, or approximately two pixels per degree, as shown in FIG. 13. In general, the dimensions of the microarray should be selected such that the viewer does not perceive the boundaries of the microarray. Parameters to consider when determining the dimensions of the microarray 202 include an array dimension that is large enough to provide improved durability and robustness, yet small enough for repairability to the array on the PCB.

[0036] As reflected in FIG. 13, the viewer's distance to the screen has a direct correlation with the ideal array dimensions, but typically the pixel pitch is also selected based on this distance. In one example, a 100×100 pixel array can be formed in accordance with the present disclosure using an array of microarrays 202 with partial pixels and pixels as small as a 2×2 array and as large as a 16×16 array, so that the microarray dimensions do not need to exceed 5 mm×5 mm. For a 2×2 microarray, the SMD footprint is four times larger than a single RGB SMD pixel, but is still small enough that it can be replaced to repair the array without becoming commercially unreasonable. It is also small enough that it is within the line of sight so that the viewer cannot see the physical pattern or division of a very large array (in other words, the "texture" of the front of a very large display appears uniform).

[0037] In one example, the dimensions of the microarray 202 may be approximately 5 mm by 5 mm or less. In a 5 by 5 mm microarray, the individual pixel dimensions may be in the range of approximately 2 by 2 mm to approximately 2.4 by 2.4 mm in some embodiments. As an illustrative example, the white LEDs 216 may comprise 6504 Kelvin or 2700 Kelvin LEDs. A further feature of the embodiments disclosed herein is that each microarray 202 may be individually encapsulated, as shown in FIG. 11. Thus, if an LED fails on one microarray, only that particular microarray needs to be replaced. The replaced microarray provides a more uniform appearance with the existing microarrays, since any variations in the encapsulation layer are internal to each microarray. Also, if a single LED fails, only a single microarray, e.g., in one embodiment, just eight LEDs, is required for replacement, resulting in much greater efficiency and less waste compared to conventional designs.

[0038] 14 shows an example of a video display or a portion of a video display comprised of microarrays 202 as disclosed herein. In this embodiment, a video display 240 comprises an array of tiles 200. Each tile is comprised of an array of microarrays 202. In this example, six tiles 200 are shown for illustrative purposes only, each containing sixteen microarrays 202. A typical real world installation would include much larger arrays, as would be understood by one of ordinary skill in the art.

[0039] In addition to the above array dimensions, as explained above, the embodiments disclosed herein do not utilize a simple RGB set for the pixels. A white pixel 216 is added at least one color temperature instead of the RGB set. In other words, instead of trying to add another sub-pixel color and further reduce the sub-pixel spacing, the embodiments disclosed herein replace three sub-pixels with fewer but different color components. This helps achieve efficiency and can also result in a uniform flat-field white point for the video display.

[0040] RGB LED pixels and white LED pixels are common configurations. Thus, while those LED pixels are used herein for illustrative purposes, the principles of the present disclosure are equally applicable to any type of light emitter that uses multi-color pixels, whether RGB LED type light emitters, other light emitter types (e.g., as non-limiting examples, organic light emitting diodes (OLEDs), polymer light emitting diodes (PLEDs), active matrix light emitting diodes (AMOLEDs), liquid crystal displays (LCDs) or light emitting electrochemical cells (LECs)), or other multi-color pixel combinations (e.g., as non-limiting examples, multi-primary color pixels having four or five colors, such as RGBY, RGBM, RGBC, or RGBYC). Thus, the scope of the present disclosure and the appended claims is not limited to the exemplary RGB LED example.

[0041] The above is a detailed description of exemplary embodiments of the present disclosure. It should be noted that the conjunctive language used in the phrases "at least one of X, Y, and Z" and "one or more of X, Y, and Z" in this specification and the claims appended hereto shall be interpreted to mean that each item in the conjunctive list can be present in any number except all other items in the list, or in any number in combination with any or all other items in the conjunctive list, and each of them can be present in any number, unless otherwise stated or indicated. Applying this general rule, the conjunctive phrase in the above example where the conjunctive list is composed of X, Y, and Z shall respectively include one or more X, one or more Y, one or more Z, one or more X and one or more Y, one or more Y and one or more Z, and one or more X, one or more Y, and one or more Z.

[0042] Various modifications and additions can be made without departing from the spirit and scope of the present disclosure. Each feature of the various embodiments described above may be combined with features of other described embodiments, as appropriate, to provide multiple feature combinations in related new embodiments. Moreover, while the above describes several separate embodiments, what is described herein is merely illustrative of the application of the principles of the present disclosure. Furthermore, although certain methods herein may be illustrated and / or described as being performed in a particular order, the ordering is highly variable within the scope of one of ordinary skill in the art to achieve aspects of the present disclosure. Thus, this description is intended to be construed as being exemplary only, and is not intended to limit the scope of the present disclosure.

[0043] Exemplary embodiments have been disclosed above and are illustrated in the accompanying drawings. It will be understood by those skilled in the art that various modifications, omissions and additions may be made to what is specifically disclosed herein without departing from the spirit and scope of the present disclosure.

Claims

1. an array of self-illuminating pixels; each pixel of said array contains the same plurality of different colored light emitters; The different color light emitters in each pixel of the array are arranged in at least one of a different order, a different orientation, or a different arrangement relative to the different color light emitters in at least two adjacent pixels of the array. Light-emitting device.

2. 10. The light emitting device of claim 1, wherein each of the different colored light emitters in each pixel is a non-white light emitter.

3. the array of pixels includes a pixel including a white light emitter and a pixel including a plurality of non-white light emitters; Each pixel having a white light emitter is adjacent to no more than four other pixels in the array that also have white light emitters. The light emitting device according to claim 1 .

4. 4. A light emitting device according to claim 1, wherein the light emitters of different colours are arranged in different orders in the at least two adjacent pixels.

5. 4. A light emitting device according to claim 1, wherein the light emitters of different colours are arranged with different orientations in the at least two adjacent pixels.

6. 4. The light emitting device according to claim 1, wherein the light emitters of different colors are arranged in different arrangements in the at least two adjacent pixels.

7. 4. A light emitting device according to any one of claims 1 to 3, wherein the array comprises a microarray of self-emitting pixels formed as a surface mounted device (SMD).

8. 4. The light emitting device according to claim 3, wherein at least two of the pixels each include the single white light emitter, and at least two of the pixels each include multiple color light emitters forming a set of partial pixels.

9. The light emitting device of claim 8 , further comprising a microarray substrate, wherein each of the light emitters is surface mounted on the microarray substrate.

10. 9. The light emitting device of claim 8, further comprising a microarray substrate to which each of the multicolor light emitters is directly bonded, and a white light emitter substrate to which the white light emitter is directly bonded, the white light emitter substrate being directly bonded to the microarray substrate.

11. 11. The light emitting device according to claim 8, wherein the white light emitter comprises a white LED, and the multicolor light emitter comprises a combination of red, green and blue LEDs.

12. 1. A light emitting device configured as a surface-mounted device that reduces off-axis color distortion from a particular viewing angle, the light emitting device comprising a 2x2 pixel microarray, one row consisting of a first pixel formed from a sequence of red, green, and blue LEDs and a second pixel formed from a single white LED, and another row consisting of a first pixel formed from a single white LED and a second pixel formed from a sequence of blue, green, and red LEDs.

13. 13. The light emitting device of claim 12, wherein each pixel has an overall height and width that are at least substantially equal.

14. A light emitting device according to any one of claims 8 to 10 or claim 12, wherein the overall height and width of each pixel varies by between about 1% and 20% of the overall height and width of each other pixel in the array.

15. 15. The light emitting device of claim 14, wherein the overall height and width of each pixel varies by about 5% to 10% of the overall height and width of each other pixel in the microarray.

16. 13. The light emitting device of claim 1, further comprising a light-transmitting encapsulation layer over light emitters or LEDs mounted on the array substrate.

17. 1. A light-emitting array for providing off-axis color correction for a video wall display, comprising an SMD having at least four pixel groups arranged in a 2x2 array, wherein vertically adjacent pixel groups and horizontally adjacent pixel groups comprise a plurality of individual light emitters that are positioned differently relative to one another, and wherein off-axis color distortion of the individual light emitters is distributed among a plurality of viewing angles to reduce or eliminate cumulative off-axis color distortion of the light-emitting display.

18. 20. A video display tile comprising a plurality of light-emitting arrays according to claim 17 formed into a tile array, the tile array having reduced off-axis color distortion configured to provide reduced or eliminated color distortion when the video display tile is viewed at a particular viewing angle.

19. forming a plurality of multicolor pixels with two different pixel arrays; and surface mounting the multicolor pixels of the microarray to a microarray substrate; each multicolor pixel comprises a plurality of different colored light emitters, each different pixel arrangement differing from the other pixel arrangements by at least one of light emitter color sequence, color light emitter orientation, or color light emitter placement, and having an overall height and an overall width; A method of manufacturing a light emitting device, wherein each multicolor pixel has a pixel arrangement that is different from its horizontally and vertically neighboring multicolor pixels.

20. forming a plurality of white light emitters; and surface-mounting the white light emitters to the microarray substrate adjacent to the multicolor pixels to form a microarray of alternating multicolor and white pixels. The method for manufacturing the light emitting device according to claim 19.

21. 21. The method for manufacturing a light emitting device of claim 20, wherein surface mounting the white light emitters comprises first surface mounting the white light emitters to individual substrates, and then separately surface mounting the individual substrates with the white light emitters onto the microarray substrate.

22. 22. The method for manufacturing a light-emitting device according to claim 19, further comprising encapsulating the light-emitting body in a light-transmitting protective layer after the light-emitting body is surface-mounted on the microarray substrate.

23. The method for manufacturing a light-emitting device according to claim 22, wherein the light emitter is configured so that the microarray has a size of 5 mm x 5 mm or less.

24. each of the multicolor pixels has an overall height and an overall width; Each of the white light emitters has an overall height and width that are substantially the same as the height and width of each of the multicolor pixels. A method for manufacturing a light emitting device according to claim 23.

25. 13. The light emitting device of claim 1 or claim 12, wherein the light emitter comprises at least one of an LED, an OLED, a PLED, an AMOLED, an LCD, or an LEC.

26. The light emitting array of claim 17, wherein the light emitter comprises at least one of an LED, an OLED, a PLED, an AMOLED, an LCD, or an LEC.

27. ​​A method for manufacturing a light-emitting device as described in claim 19, wherein the light-emitting element includes at least one of an LED, an OLED, a PLED, an AMOLED, an LCD, or an LEC.

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