LED Display De-Mura Layout for High-Resolution Color Uniformity

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Solution Overview

Problem

High-resolution LED display devices suffer from the mura effect due to uneven color and light intensity distribution among LED chips, leading to visible color differences between adjacent pixels, which current hardware and software solutions fail to adequately address.

Innovation Solution

A method involving a substrate with adjacent regions and mounting blocks, where LED chips are arranged in a partial overlapping configuration and controlled by controllers to mix light emissions, mitigating mura effects through circuit layout and light modulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If mass transfer technique is used to arrange LED chips from different regions of the wafer, then productivity is improved, but color uniformity deteriorates due to uneven distribution of color and light intensity among LED chips from different wafer regions

Engineering Contradiction:
Improvemass transfer efficiencyVSAvoidcolor uniformity
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating a de-mura region with a specific overlapping structure where LED chips from different wafer regions are arranged in an interlaced pattern. This local structural modification ensures that the transition zone between different chip arrays has mixed light emission properties, thereby improving color uniformity in the critical boundary region while maintaining overall mass transfer productivity.

Inventive Principle:
Principle #3Local quality

2Measurement precision

If LED chip size is reduced to achieve high resolution, then display resolution is improved, but the mura effect becomes more pronounced due to increased sensitivity to color and intensity variations

Engineering Contradiction:
Improvedisplay resolutionVSAvoidmura effect visibility
Core Design Contradiction:
Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent addresses the mura effect by introducing a spatial dimension solution through the overlapping region structure. Instead of modifying individual chip properties, it creates a two-dimensional interlaced arrangement where chips from different wafer regions overlap in a patterned fashion. This dimensional approach allows light mixing across the boundary, effectively suppressing the mura effect in high-resolution displays where individual chip variations are more visible.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Manufacturing precision

If software color calibration is applied to each pixel, then color accuracy is improved, but device complexity increases due to additional control circuits and processing requirements

Engineering Contradiction:
Improvecolor accuracyVSAvoidcontrol circuit complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts the color uniformity function from the electronic control domain and implements it through a passive optical structure. By creating the overlapping de-mura region with interlaced chip arrangement, the system achieves color mixing and uniformity through physical light superposition rather than active electronic calibration. This extraction of the color correction function from complex control circuits to a simple structural design significantly reduces device complexity while maintaining color accuracy.

Inventive Principle:
Principle #2Taking out (Extraction)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method effectively reduces visible color differences by ensuring uniform light mixing and intensity across adjacent pixel arrays, enhancing display performance and reducing mura defects.

Implementation Method 1

The first LED chip array includes a plurality of first LED chips. The second LED chip array includes a plurality of second LED chips

Methodology Applied
Scientific EffectLight emission: Light Emitting Diode

Implementation Method 2

controlled by controllers to mix light emissions, mitigating mura effects through circuit layout and light modulation

Methodology Applied
Scientific EffectLight mixing:

Data Source

PatentUS12494457B2Light-emitting diode display device and method of manufacturing the same
Publication Date: 2025.12.09 ENNOSTAR CORP
  • US12494457B2 patent drawing
  • US12494457B2 patent drawing
  • US12494457B2 patent drawing

AI summary

A light-emitting diode (LED) display device, including a substrate, a de-mura region, a plurality of mounting blocks, a first LED chip array and a second LED chip array, is disclosed. The substrate includes a first region and a second region adjacent to each other. The de-mura region includes part of the first region and part of the second region. The mounting blocks are arranged in the first and the second region as an array, each mounting block including a first and a second mounting part. The first and the second mounting part are connected in parallel. The first LED chip array includes multiple first LED chips. The second LED chip array includes multiple second LED chips. Each first mounting part is arranged on the first side of the corresponding mounting block, and each second mounting part is arranged on the second side of the corresponding mounting block.