Micro-LED displays present significant repair challenges at scale, where defect rates of even 0.1% translate to thousands of non-functioning pixels in a 4K display. Individual pixel repairs require precise manipulation at the microscale, typically 3-100 micrometers, while maintaining alignment accuracy within 1-2 micrometers to preserve display uniformity.

The fundamental challenge lies in achieving reliable pixel repair without compromising adjacent functional elements or introducing visible artifacts that affect display quality.

This page brings together solutions from recent research—including laser-assisted transfer methods, redundant circuit architectures, mass transfer repair techniques, and color-mapped spare pixel approaches. These and other approaches focus on maintaining display quality while improving repair yields in production environments.

1. Display Device with Electrically Disconnected Conductive Patterns and Reversible LED Connection Mechanism

SAMSUNG DISPLAY CO LTD, 2025

Display device with improved reliability and repairability by preventing or substantially preventing dark spot defects in subpixels. The display has separate first and second conductive patterns that are electrically disconnected from each other. The subpixel electrodes are also disconnected from each other. This allows replacing a reversed connected defective LED without removing it. A laser is used to cut the connections between the electrodes and underlying conductive patterns, then connect them in the correct forward direction. This allows reusing the defective LED by changing its driving current direction. Having multiple sub-electrodes per end of the LED provides redundant current paths to improve reliability.

2. Display Device with Selective Adhesive Layer and Mask-Assisted LED Transfer Mechanism

LG DISPLAY CO LTD, 2025

Display device with improved transfer process for LED arrays to prevent defects when transferring the LEDs to the display panel. The display device has an adhesive layer on the panel with selective areas that adhere to the LEDs. During transfer, a mask is used to cure and prevent adhesion on the selective areas. This allows transferring only the LEDs in contact with the adhering areas while avoiding transfer of unplaced LEDs. The non-adhering areas provide space for LED repositioning. The adhesive force is higher on the LED contact areas. This prevents transfer defects like LEDs going to wrong positions.

US2025126930A1-patent-drawing

3. Transparent Display Device with Stacked Reserve Sub-Pixels and Transparent Electrodes

LG DISPLAY CO LTD, 2025

Transparent display device with improved resolution and repair capability. The display has sub-pixels containing red, green, and blue LEDs, along with a reserve sub-pixel with stacked red, green, and blue LEDs. If any LED in a normal sub-pixel fails, the reserve LEDs can replace them. Stacking the reserve LEDs reduces area compared to parallel LEDs. The reserve LED electrodes are transparent to allow light from lower LEDs to escape. This allows repair and area savings while maintaining light output.

4. Display Device with Modular Assembly Featuring Coupling Members for Component Replacement

LG ELECTRONICS INC, 2025

Display device with easily replaceable parts for improved repairability and recyclability compared to sealed devices. The display has a display panel sandwiched between an inner plate and a support plate. Coupling members connect the inner plate and support plate. This allows disassembly and replacement of just the inner panel or support plate without disturbing the rest of the display. The main frame holds the display panel and has features like guides, fasteners, and a bottom frame for securing the display. This enables easy removal and replacement of just the display panel or inner components, facilitating repair, recycling, and disassembly.

US2025126971A1-patent-drawing

5. Display Panel with Dual Redundant Gate Driving Circuits for Continuous Operation

LG DISPLAY CO LTD, 2025

Display panel design that allows continuous operation of a display device even if one of the gate driving circuits fails. The display panel has two gate driving circuits, one on each side, that provide gate pulses to the display's gate lines. If one driving circuit starts to malfunction, the other circuit takes over and provides single-fed gate pulses to the affected gate lines. This prevents image defects and improves reliability by allowing the display to keep functioning when one gate driver fails.

6. Flexible Electronic Device with Overlapping Bumps and Variable Spacing for Enhanced Component Replacement

INNOLUX CORP, 2025

Flexible electronic device with overlapping bumps for improved repairability of large display tiles. The device has a substrate with adjacent through holes and overlapping bumps. The bumps are adjacent along a direction. The electronic element is overlapped with the substrate and electrically connected to one of the bumps. The distance between the through holes is different from the distance between the bumps in the overlapped direction. This allows replacing a damaged bump without removing the undamaged bump and element. The substrate separates the replaced bump from the element.

US2025118230A1-patent-drawing

7. Micro Flip Chip Transfer Method Utilizing Conductive Adhesive and Laser-Induced Gasification for Reusable Bonding Positions

TAN KAH KEE INNOVATION LABORATORY, XIAMEN UNIVERSITY, 2025

Transfer method for micro flip chips that allows reusing original bonding positions after defective chips are removed. The method uses conductive adhesive as the bonding material between the micro flip chips and substrate. Laser irradiation separates defective chips by causing gasification of the adhesive, without damaging the substrate contacts. The adhesive absorbs laser energy and expands, generating airflow to lift off the chips. This immediate separation prevents contact damage from prolonged laser exposure.

US2025120233A1-patent-drawing

8. Micro LED Display Element with Integrated Common Electrode Structure and Vacuum Repair Capability

BOE TECHNOLOGY GROUP CO LTD, HEFEI BOE RUISHENG TECHNOLOGY CO LTD, 2025

Micro LED display element with reduced missing pixel defect and improved yield. The element has multiple LEDs packaged together with common electrodes and pads. This allows bonding all LEDs at once instead of separately. The shared electrodes and pads eliminate interference and misalignment issues during die bonding. It also reduces bonding time compared to individual LEDs. The larger element size enables repair through vacuum adsorption holes.

US2025120236A1-patent-drawing

9. Image Array Pixel Defect Detection via Statistical Analysis of Neighboring Pixel Sets

TRIEYE LTD, 2025

Detecting defective pixels in an image array using statistical analysis on sets of surrounding pixels. For each pixel, a cell with neighboring pixels is analyzed statistically. If the statistical distance of the pixel from the cell exceeds a threshold, it indicates a defective pixel. This provides a way to detect defective pixels without relying on calibration or edge detection, as the statistical outlier can be identified on-the-fly during image processing.

10. LED Display Panel with Electrode Pads Featuring Reconfigurable Connections via Meltable Areas

SHANGHAI TIANMA MICRO-ELECTRONICS CO LTD, 2025

Display panel and device design to save space and improve repairability by eliminating the need for backup electrodes in LED displays. The panel has electrode pads with three areas: a main area for the LED, and two connecting areas. If an LED fails, the connection between the main and connecting areas can be disconnected by melting the lower melting point connecting area. This allows moving the LED to the spare connecting area without needing a separate backup pad. The reduced width connecting areas save space compared to separate backup pads.

US2025112215A1-patent-drawing

11. Display Panel with Enlarged Electrode Pad Projections for Enhanced Element Replacement and Alignment

TIANMA ADVANCED DISPLAY TECHNOLOGY INSTITUTE CO LTD, 2025

Display panel design with improved yield and repairability. The display panel has an array of light-emitting elements on one side of a substrate. Each light-emitting element has a first binding electrode connected to a first pad and a second binding electrode connected to a second pad in the pixel region. The area of the first pad projection exceeds twice the first binding electrode projection, and the second pad projection exceeds twice the second binding electrode projection. This reduces alignment difficulties and enables bonding the replacement element within the original pixel region without repairing the pads. The larger pad areas simplify repair compared to redundant pads. The display has improved yield and repairability without impacting resolution.

12. Display Apparatus with MicroLED Drivers and Clock-Controlled Diagnostic Mode During Vertical Blanking

AUO CORP, 2025

Display apparatus with improved diagnostics for microLED displays. It allows detecting panel issues during vertical blank periods when the display is off. The display has multiple microLED drivers with timings controlled by separate clock signals. During blanking, all clock signals go low to disable emitting in all pixels. This lets detecting abnormalities like stuck pixels.

13. Display Control Method with Dynamic Image Adjustment for Partial Hardware Failure

PANASONIC AUTOMOTIVE SYSTEMS CO LTD, 2025

Display control method to improve user experience when display hardware fails by dynamically adjusting the displayed image to fit around failed regions. When a failure is detected in a display, the controller identifies the remaining unfailed region and reconstructs the displayed image to fit within that area. This allows continuing to display an image with reduced size or distortion instead of a blank screen. The controller can also divide the remaining regions across multiple displays to maintain the original size. This prevents narrowing or distorting the image and improves user experience compared to treating a partial failure as a full screen failure.

US2025108692A1-patent-drawing

14. Wiring Substrate with Spaced Connection Ends Forming Bonding Pad Groups for Parallel Die Bonding

BOE TECHNOLOGY GROUP CO LTD, 2025

Wiring substrate for mini LED displays that improves yield and manufacturing efficiency. The substrate has connection wires with adjacent pairs of ends arranged spaced apart. These pairs define bonding pad groups. The pads are sub-bonding pads from the adjacent pairs. This allows die bonding parallel to the pad groups for multiple LEDs at once. It reduces movement errors compared to bonding perpendicular to the pads. It also enables repositioning damaged pads by swapping LED pairs.

US2025113695A1-patent-drawing

15. Electronic Device Signal Transmission with Inter-Substrate Metal Layer for Electrode Signal Continuity

INNOLUX CORP, 2025

Assisting signal transmission in electronic devices like displays by adding metal layers between the substrates to provide a backup path for electrode signals if the bonding connections fail. The metal layer is disposed between the substrates and the bonding regions to electrically connect them. This allows signals to still be transmitted through the metal layer if the bonding fails, preventing device failure. The metal layer is located outside the active area to avoid affecting device performance.

US2025110373A1-patent-drawing

16. Layer Transfer Method Utilizing Patterned Bonding Template and Reusable Repair Wafer with Liquid-Assisted Selective Area Transfer

INTEL CORP, 2025

Selective layer transfer technique to enable transferring specific areas of a layer from a donor substrate to a receiver substrate instead of full layer transfers. The technique uses a patterned bonding template on the receiver substrate and a reusable repair wafer with hydrophobic marks containing liquid droplets placed in areas matching the deficiencies of the donor wafer. The liquid capillary force between the droplets and deficient areas allows selective transfer of bad dies during a debonding process. The repair wafer can be reused for subsequent repairs on other donor wafers.

17. Display Apparatus with Detachable Panel and Rear Chassis Holder for Non-Destructive Replacement

SAMSUNG ELECTRONICS CO LTD, 2025

Display apparatus with detachable display panel for easy replacement without damaging the display. The display has a rear chassis covering the back of the display panel. The panel has a holder on the rear facing the chassis. Wires connect the holder to the chassis. By separating the wires, the holder detaches from the chassis allowing the panel to be removed. This enables swapping out the display panel without disassembling the entire display.

US12265419B2-patent-drawing

18. Display Pixel Luminance Degradation Compensation via Real-Time Sensing Current Analysis

SAMSUNG DISPLAY CO LTD, 2025

Compensating for luminance degradation of individual pixels in a display to improve image quality over time. The compensation is done by measuring the sensing current of each pixel during blank periods between frames. This current is compared to a reference value to calculate a deterioration weight for each pixel. This weight is then applied to the pixel's output image data to compensate for luminance degradation. By measuring and compensating for pixel degradation in real time based on usage, image quality is maintained as pixels age.

19. Contactless Micro LED Inspection System Utilizing Pulsed Laser-Induced Photovoltaic RF Signal Detection

Orbotech Ltd., 2025

Contactless micro LED inspection system that uses pulsed lasers to detect defective micro LEDs without direct electrical testing. The system emits pulsed lasers at the LEDs to generate photovoltaic radio frequency signals when radiated. An antenna receives these signals, which are amplified and analyzed by a processor to determine if the LED is functioning or defective. This allows high-efficiency, contactless testing of micro LED arrays without needing to electrically test each individual tiny LED.

US20250102558A1-patent-drawing

20. Display Device with Variable Thickness Bank Layer Surrounding LED Areas

LG Display Co., Ltd., 2025

Display device with improved brightness uniformity, reduced staining, and higher charging efficiency at low brightness levels. The display has a bank layer surrounding the LED areas. The bank layer thickness varies between areas. A thinner bank area adjacent to the LEDs prevents residual films in the micro-lenses. A thicker bank area away from LEDs absorbs laser repair beams to block current. This prevents visual artifacts when repairing defective subpixels without affecting adjacent subpixels. The varying bank layer thicknesses balance brightness, staining, and repair isolation.

21. Composite Integrated Film with Base Member Penetrations for Element Testing and Replacement

22. Transparent Display Substrate with Scanning Line Outer Ring Portions for Enhanced Electrical Connectivity and Repairability

23. Display Panel Repair Method with Selective Subpixel Component Replacement via Cathode Connection Reconfiguration

24. Display Device with Stacked Transparent Repair Substrate Incorporating Replacement Micro LEDs

25. Light Emitting Display Incorporating Test Pixels for Defect Diagnosis

Innovative methods make repairing micro-LED components simple ᅳeven at the pixel levelᅳwhich reduces micro-LED waste and makes adoption for all kinds of display applications more sustainable. Accurate color reproduction and low power consumption are further benefits.

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