Micro-LED displays face integration challenges at multiple scales: individual LED chips measure 1-10 micrometers, while complete display modules span hundreds of millimeters. At these scales, visible defects emerge from both manufacturing variations and assembly tolerances—including linear seams between tiled modules and light leakage between adjacent pixels that can degrade image quality.

The fundamental challenge lies in achieving seamless visual integration of micro-LED modules while maintaining manufacturability and yield at production scales.

This page brings together solutions from recent research—including recessed module designs that minimize visible seams, advanced collimation structures that reduce pixel crosstalk, embedded chip architectures that improve reliability, and multi-layer circuit designs that enable higher density integration. These and other approaches focus on practical manufacturing methods while delivering the visual performance demanded by commercial signage applications.

1. Micro LED Array Display with Flip Chip Bonded Pixels on CMOS Backplane

LUMENS Co., Ltd., 2023

Micro LED array display device that enables individually driving and controlling micro LED pixels using flip chip bonding on a CMOS backplane. The display has a micro LED panel with multiple pixels, a CMOS backplane with cells corresponding to each pixel, and bumps between them. The micro LED pixels are flip chip bonded to the CMOS cells to drive them individually. This simplifies wiring and eliminates data lines compared to connecting each pixel. The display can also be a full color implementation with red, green, and blue micro LED panels bonded to the same CMOS backplane.

2. LED Control Circuit with Independent Drive Modules and Centralized Protocol-Based Coordination

SHENZHEN JINHUIXIN INTELLIGENT TECH CO LTD, SHENZHEN JINHUIXIN INTELLIGENT TECHNOLOGY CO LTD, 2023

LED light control circuit for intelligent electronic signs that allows display of different images on multiple LED modules based on user instructions. The circuit has separate drive modules for each set of LEDs. This allows each set to be independently controlled for customized displays. A central control module coordinates the drive modules and communicates with them using a protocol like DMX512. This allows complex synchronized displays across multiple LED sets.

CN117012142A-patent-drawing

3. Modular Micro LED Display with Side Surface Connection Terminals and Integrated Synchronization Controller

JO SUNG HYUN, 2023

Micro LED display device that can be connected to neighboring micro LED displays to form a tiled display system without requiring individual setup. The displays have terminals on their side surfaces to connect to adjacent displays. Each display contains a controller that can communicate with connected displays using packets containing arrangement and identification data. This allows the displays to exchange data and synchronize without a central controller.

KR102527697B1-patent-drawing

4. MicroLED Display with Cluster-Based Current-Selectable Controllers

X Display Company Technology Limited, 2023

Current-selectable microLED displays that improve power efficiency by matching the electrical current range to the pixel luminance range. The displays use clusters of microLEDs controlled by dedicated cluster controllers. Each cluster controller has a selectable current source that provides a specific range of currents. The controllers choose the right current level based on the pixel brightness to avoid unnecessary power waste. This reduces leakage in the current sources and improves efficiency compared to fixed-current sources. The clusters can be arranged over the microLED array to enable this per-pixel current customization.

US11568796B1-patent-drawing

5. Pixel Drive Circuit with Separate Current and Light Emission Control for MicroLED Displays

BOE Technology Group Co., Ltd., 2022

Pixel drive circuit for microLED displays that improves luminance, gray scale and stability. The circuit has separate current and light emission control circuits. The current control circuit outputs a fixed current to the microLED, keeping it at a high current density where efficiency is stable. The light emission control circuit pulsed drives the microLED using a capacitor charged by a variable voltage. This allows precise control of emission time. The fixed current and pulsed emission together optimize microLED performance.

6. MicroLED Display with Substrate-Integrated Conductive Pathways for Separated Driver Circuitry

Intel Corporation, 2022

Reducing pixel pitch of microLED displays by separating the driver circuitry from the microLED array. The microLED matrix is on one side of a substrate and driver circuits are on the other side. Conductive paths in the substrate connect the microLEDs to the drivers. This allows reducing pixel size beyond the microLED size limitation. A separate driver circuit provides scan and PWM signals to the matrix drivers. The matrix drivers then control the microLEDs based on the scan and PWM signals.

7. MicroLED Display Incorporating In-Pixel Pulse Width Modulation Circuits with Compact Transistor Configuration

Intel Corporation, 2022

MicroLED display with in-pixel pulse width modulation (PWM) circuits to improve power efficiency and color accuracy at low grayscale levels compared to traditional column-based PWM. Each pixel has a compact PWM circuit that converts low-frequency sawtooth or triangular pulses from the column drivers into PWM pulses to drive the microLED. This allows using longer pulses from the column drivers instead of short high-frequency pulses, reducing power consumption. A digital-to-analog converter provides the grayscale data. The in-pixel PWM circuits have 7 or fewer transistors for compactness.

US2022198995A1-patent-drawing

8. Micro LED Display Screen with Modular Power Control for Individual LED Module Deactivation

SHENZHEN OUTOELECTRON CO LTD, 2022

Energy-saving Micro LED display screen that reduces power consumption by allowing individual LED modules to be turned off when not in use instead of the entire display. The display has a main control module, power supply module, and multiple LED modules. Each LED module has an interface to connect to the control and power modules. The control module converts video data and sends it to the LED modules. The power module supplies power to the display. When a module is not needed, the control module can disable power to that module instead of the whole display.

9. Micro LED Display with Pixel Array Circuit Board and Integrated Signal Compensation Controller

PLAYNITRIDE DISPLAY CO LTD, 2022

Micro LED display with high resolution and compact layout to improve display quality and density. The micro LED display has a circuit board with micro LEDs having pixel arrays. A controller on the board drives the micro LEDs. The controller has an interface, data driving circuit, and core circuit. The interface receives command/data signals. The core circuit generates compensated display info based on micro LED arrangement in each pixel. The data driving circuit generates control signals for the micro LEDs using the compensated info. This allows packed micro LED displays with high resolution and compact layout as the controller optimizes the display signal for each micro LED.

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10. Micro LED Display with Single Controller for Compensated High-Resolution Output

PlayNitride Display Co., Ltd., 2022

Micro LED display with high resolution and improved display quality using a single controller. The display has closely packed micro LED devices on a circuit board. A single controller drives the micro LEDs by transmitting signals to control their display statuses. The controller calculates compensated display data based on the micro LED arrangement to improve image quality. By reducing the pitch between micro LEDs and using a single controller, the display resolution is increased compared to one-to-one control.

US2022059015A1-patent-drawing

11. LED Display Control Device with Weighted PWM Signal for Enhanced Image Reproduction

O SUNG TELECOM CO LTD, O-SUNG TELECOM CO LTD, 2021

An LED display and control device that allows high-quality image reproduction on displays with commercial LED components, even when the components have limited response times. The solution involves generating an image control signal with a pulse width modulation (PWM) technique that reflects a preset weight. This weight is determined based on the shift clock period and basic pulse count. The weight determines the time between enabling LEDs, allowing fine control within the component's response time. It allows high-quality images with shorter PWM periods and faster refreshes, even on displays with commercial LED modules.

12. Direct View LED Display with Intelligent Pixel Processing and Virtualization for Enhanced Resolution

ATLURI VENKATA RAM, MAGANTI VENKATA RAMANA RAO, 2021

Direct view LED display system with optimized resource utilization and image quality to enable higher resolution LED displays with reduced footprint and thickness. The system uses techniques like intelligent pixel processing, scan++, and virtualization to multiply effective pixel count without losing content or quality. It arranges individual RGB LEDs in a matrix and processes pixel data using software to form perception pixels by combining neighboring LEDs. This reduces the number of physical LEDs needed by 60% while maintaining image fidelity.

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13. LED Display Device with Dual Emission Spectra and Embedded Reflective Layers

LG DISPLAY CO LTD, 2021

LED display device with improved brightness, resolution and defect prevention. The display uses LED elements with dual emission spectra controlled by separate pixel drivers. This allows higher brightness and definition compared to single-spectrum elements. It also prevents defects by replacing a faulty LED without affecting other pixels. The display can be double-sided by embedding reflective layers between the LEDs and substrate.

KR20210079588A-patent-drawing

14. LED Display Unit with Integrated Flip-Chip LEDs, Bare Crystal Current Drivers, and Control Module on a Unified Substrate

Xiong Zoucheng, ZHOUCHENG XIONG, 2021

An LED display unit with integrated electronics for micro-pixel pitch displays that improves image stability and simplifies assembly compared to external driver boards. The display unit has flip-chip LEDs, bare crystal current drivers, and an integrated control module all on the substrate. This allows direct connection between the LEDs and drivers without external cables, improving image consistency and reducing assembly complexity compared to separate boards. The integrated driver layout allows higher LED densities with smaller pitch displays.

CN111599306B-patent-drawing

15. Transparent LED Display with Flexible PCB and Concave-Convex Base Panel

Wi In-ho, 2020

Digital signage transparent LED display that provides clear high-resolution images on a transparent background. The display uses a flexible printed circuit board (PCB) with optimized circuit patterns to supply the rated current to each LED chip. This prevents resistance issues and improves brightness compared to glass or film-based displays. The PCB is inserted into a concave-convex transparent base panel with LED modules. The display has a removable cover and frame for installation flexibility. The flexible PCB and LED insertion process allows customized color and resolution configurations.

KR102173410B1-patent-drawing

16. Micro LED Display with Redundant Subpixel Configuration for Rotational Activation

Intel Corporation, 2020

Micro LED display with redundant subpixels to improve lifetime and mitigate burn-in. Each pixel has primary subpixels and redundant backup subpixels. The primary subpixels are used initially to display the image. After a threshold usage, the backup subpixels are enabled instead. This rotates the active subpixels to spread wear and prevent burn-in. The display has primary and backup red, green, and blue subpixels for each pixel. A controller switches between using the primary or backup subpixels based on usage.

17. MicroLED Display with Independent Current and Emission Duration Control for Each Color

KYOCERA CORP, 2020

MicroLED display with efficient color mixing and reduced complexity by independently controlling the current and emission duration of each microLED color instead of using separate green and blue microLEDs. The display has red, green, and blue pixel units with dedicated current and period switches for their respective microLEDs. This allows precise control of the current and duty cycle for each color instead of using separate green and blue microLEDs. The switches are connected to a central light emission control unit. This enables efficient color mixing and reduces complexity compared to separate green and blue microLEDs.

18. Display Unit Board with Integrated Mini 4-in-1 RGB LED Chips and Onboard Calibration Storage

ZHEJIANG DEGUANGXIN ELECTRONIC TECH CO LTD, ZHEJIANG DEGUANGXIN ELECTRONIC TECHNOLOGY CO LTD, 2020

Display unit board for LED screens with improved pixel density and simplified manufacturing. The board has mini 4-in-1 RGB LED chips mounted directly on the PCB instead of separate red, green, and blue chips. This reduces the number of components and allows closer pixel pitch. The board also integrates an intelligent storage chip to store calibration data and LED info, eliminating the need for external flash modules. The board connects directly to the control system without calibration steps. The integrated chips, compact layout, and onboard storage simplify manufacturing compared to dispersed components and external flash.

19. MicroLED Display Structure with Light Blocking and Guiding Layers for Enhanced LED Separation and Electrical Connectivity

Prilit Optronics, Inc., 2020

MicroLED displays with improved contrast and uniformity for large-size, high-resolution displays. The displays use a structure where microLEDs are separated by light blocking layers and surrounded by light guiding layers. This prevents interference and color mixing between adjacent LEDs. The LEDs are electrically connected through internal structures. The displays can be top emission (LEDs face the display substrate) or bottom emission (LEDs face away from the substrate). The light blocking and guiding layers enable dense packing of closely spaced LEDs without interference.

20. MicroLED Display Backplane with Integrated Local Memory for Independent Pixel Control

Intel Corporation, 2020

Integrating local memory into microLED displays to improve performance and power efficiency. The displays have a backplane with an array of microLEDs and additional memory elements mounted between the LEDs. Each LED is driven using the local memory for that pixel, allowing independent pixel updates without needing to access a remote memory. This reduces data bandwidth and latency compared to driving all pixels from a central memory. It also enables features like per-pixel memory, power optimization, and local compute.

US2020135093A1-patent-drawing

21. Seamless Spliced Display with Integrated LED Modules on Transparent Substrate

22. Modular LED Display with Independent Pixel Control and Integrated Circuit-Driven Matrix

23. LED Display Unit Board with Mini4-in-1 Full-Color LED Chips and Integrated Driver Circuitry

24. Display Apparatus with Cuttable and Shapeable Configurable LED Modules and Individually Addressable Pixels

25. Micro LED Display Device with Time-Sharing Fabry-Perot Light Control Layer

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