Display Pixel Transfer by Optical Binning for Color Uniformity

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Solution Overview

Problem

Existing display device manufacturing methods face issues with optical characteristic deviations among light-emitting elements, leading to uneven color in display images and reduced utilization rates due to inconsistent light mixing results.

Innovation Solution

A method involving the grouping and transfer of light-emitting units based on their optical characteristics to align the color point of the display device with a predetermined target color point, using a combination of first and second light-emitting units emitting different colors and employing wavelength conversion elements when necessary.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If light-emitting elements with different optical characteristics are used, then the utilization rate of light-emitting elements is improved, but the color uniformity of the display image deteriorates

Engineering Contradiction:
Improveutilization rate of light-emitting elementsVSAvoidcolor uniformity of display image
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent segments light-emitting elements into different groups based on their optical characteristics (wavelength, luminance). By measuring and categorizing each element's properties, the system divides the homogeneous batch into heterogeneous groups that can be strategically assigned to different pixel locations to achieve target color points while maintaining overall uniformity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by assigning specific optical characteristic combinations to specific pixel locations based on the display panel's color requirements. Different regions of the display may use different combinations of light-emitting elements with varying wavelengths and luminances to achieve the desired color point at each location, thereby maintaining overall color uniformity while utilizing diverse elements.

Inventive Principle:
Principle #3Local quality

2Manufacturing precision

If only light-emitting elements with the same optical characteristic are used, then the color uniformity of the display image is improved, but the utilization rate of light-emitting elements deteriorates

Engineering Contradiction:
Improvecolor uniformity of display imageVSAvoidutilization rate of light-emitting elements
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent changes the approach from using elements with identical parameters to using elements with varied parameters (wavelength, luminance). By measuring actual optical characteristics and using these parameters to determine assignment strategies, the system transforms the problem from one of uniformity to one of controlled diversity, where parameter variations are leveraged to achieve target color points.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent implements feedback by measuring the optical characteristics of each light-emitting element and using this information to determine its optimal assignment. The measurement results feed into an assignment algorithm that considers target color points and pixel requirements, creating a closed-loop system that optimizes both utilization rate and color uniformity based on actual element properties.

Inventive Principle:
Principle #23Feedback

3Device complexity

If light-emitting elements with deviations in optical characteristics are used, then the manufacturing complexity is reduced, but the luminance uniformity of the display image deteriorates

Engineering Contradiction:
Improvemanufacturing complexityVSAvoidluminance uniformity of display image
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by measuring and characterizing the optical properties of light-emitting elements before they are assigned to pixel locations. This pre-measurement and pre-categorization step allows the system to account for variations in wavelength and luminance in advance, enabling optimal assignment that compensates for these variations and achieves uniform display performance.

Inventive Principle:
Principle #10Preliminary action

Data Source

PatentUS12543404B2Method for manufacturing display device
Publication Date: 2026.02.03 INNOLUX CORP
  • US12543404B2 patent drawing
  • US12543404B2 patent drawing
  • US12543404B2 patent drawing

AI summary

A method for manufacturing a display device is disclosed. The method includes providing a plurality of first light-emitting units and a plurality of second light-emitting units, the first light-emitting units and the second light-emitting units configured to emit light with different colors; obtaining an optical character of each of the first light-emitting units and the second light-emitting units; predetermining a target color point for the display device; and transferring a portion of the first light-emitting units and a portion of the second light-emitting units to a target substrate based on the obtained optical characters for aligning a color point of the display device with the target color point.