Micro-LED displays face distinct visual challenges at viewing distances under 30cm, where the physical gaps between pixels become perceptible as a screen door effect. Current designs achieve pixel densities of 200-300 PPI, but even at these resolutions, the inactive areas between emitters can create visible mesh patterns that degrade image quality and viewer immersion.

The fundamental challenge lies in maximizing the active emission area while maintaining the electrical isolation and thermal management requirements of densely packed micro-LED arrays.

This page brings together solutions from recent research—including curved light diffusion layers, anisotropic optical stacks, optimized sub-pixel LED distributions, and multi-layer diffusion techniques. These and other approaches focus on practical methods to improve perceived image continuity without compromising display brightness or reliability.

1. Micro LED Display Panel with Uniformly Distributed Sub-Pixel Micro LED Array

SHENZHEN CHINA STAR OPTOELECTRONICS TECHNOLOGY CO., LTD., 2018

Micro LED display panel with improved resolution, reduced screen door effect, and lower cost compared to conventional micro LED displays. The panel has an array of sub-pixel areas on the substrate, each filled with uniformly distributed micro LEDs. This allows higher resolution by packing more LEDs in each sub-pixel without increasing inter-pixel gaps. By optimizing the number of LEDs per sub-pixel, it balances resolution, screen door effect, and cost compared to using a single large LED per sub-pixel. The micro LEDs are transferred using a process like micro transfer printing.

US10002915B2-patent-drawing

2. Display Device with Micro LED Sub-Pixels Incorporating Planarization and Optical Layers for Enhanced Light Containment

LG DISPLAY CO LTD, 2025

Display device using micro LEDs with improved light efficiency and display performance. The display has sub-pixels with emitting areas and non-emitting areas. Each sub-pixel has multiple micro LEDs covered by a planarization layer with openings. Optical layers fill the openings to cover the micro LEDs. This design allows light emission from the micro LEDs to be trapped and guided by the optical layers instead of escaping through the sides. The planarization layer and optical layers prevent light leakage through the gaps between the micro LEDs.

3. Display Device with Micro-LEDs Surrounded by Non-Overlapping Scattering Layer

LG DISPLAY CO LTD, 2025

Display device using micro-LEDs with improved brightness uniformity and reduced power consumption by surrounding the micro-LEDs with a scattering layer. The scattering layer surrounds the bonding layers connecting the micro-LEDs to the substrate. This prevents the micro-LEDs and scattering layer from overlapping when transferring the micro-LEDs, which can cause misalignment and uniformity issues. By surrounding the bonding layers with scattering, it extracts more light from the micro-LEDs and provides consistent brightness from all viewing angles.

4. Sidewall Suppression and Top Surface Enhancement of Light Extraction Efficiency in Vertically Stacked Full‐Color Micro‐LEDs Based on L‐Shaped Metal Walls

h x guo, jun he, jie sun - Wiley, 2025

Abstract Micro lightemitting diodes (MicroLEDs) are regarded as the core of nextgeneration display technology due to their high brightness and energy efficiency. However, reduction in size MicroLEDs has led increased manufacturing challenges exacerbated issues such sidewall emission, which hinder development highpixeldensity displays. This paper proposes a vertically stacked MicroLED design based on an Lshaped metal wall structure, aiming suppress emission enhance top light extraction efficiency (LEE). Through parameter scanning, dimensions thickness epitaxial layer optimized. Combined with inclined sidewalls reflective structure wall, optical characteristics red, green, blue analyzed using raytracing simulations. The is significantly reduced (with maximum 68.04% compared without walls), enhanced (the LEE within 90 direction for blue, red by 196.18%, 51.69%, 3.45%, respectively, walls). simulation results demonstrate potential fullcolor displays, providing new approach suppressing crosstalk improving performance.

5. Display Device with Central Optical Module and Light Blocking Layer for Distortion Mitigation

SAMSUNG DISPLAY CO LTD, 2025

Display device with an optical module that provides an improved image by mitigating distortion and artifacts. The display has a lower substrate with areas around an optical module area. The optical module is in the center area. An upper substrate covers the light emitting area. A filling layer between the upper and lower substrates fills the center area. A light blocking layer surrounds the center area on the upper substrate. This configuration reduces external light introduction into the optical module while preventing wavefront distortion.

US12336418B2-patent-drawing

6. Light Emitting Element Arrangement with Shared Lens for Uniform Appearance

MAKITA CORP, 2025

Arranging multiple light emitting elements for a display device or work machine in a way that reduces differences in appearance when viewed through a shared lens. The display device has a support structure inside the housing that holds two or more light emitting elements emitting light in the same direction. A shared lens propagates the light from the emitting elements to the outside. This allows communization of the lens between the emitting elements, reducing efficiency losses from individual lenses. But by arranging the emitting elements with similar characteristics, it minimizes differences in the displayed lighting appearance viewed through the shared lens.

7. Display Substrate with Pixel Circuits Incorporating Sequential Light Emission and Shared Current Control for Enhanced Resolution

BOE TECHNOLOGY GROUP CO LTD, 2025

Display substrate for near-eye displays like AR/VR headsets with improved resolution and reduced screen door effect. The display has a matrix of pixel circuits with multiple connected light emitting devices per circuit. Each pixel circuit has a current control sub-circuit and a light emitting selection sub-circuit. The current control sub-circuit provides drive current to a shared node. The light emitting selection sub-circuit sequentially connects the node to multiple light emitting devices of the same color. This allows higher resolution by connecting multiple light emitting devices per circuit instead of one per pixel. The selection sub-circuit prevents simultaneous light emission. The display also has features like stacked transistors, overlapping connections, and separated color emitting devices to further optimize resolution and performance.

US12322331B2-patent-drawing

8. Display Device with Stacked Structure and Graded Refractive Index Insulating Layers

SAMSUNG DISPLAY CO LTD, 2025

Display device with improved light extraction efficiency and display quality by reducing internal reflections. The display has a stacked structure with a substrate, transistor, light emitting element, encapsulation layer, sensing electrode, and insulating layers. The insulating layers have progressively increasing refractive indices from the bottom to the top. This graded index structure helps light rays escape the device by reducing total internal reflections at the interfaces between layers.

US12310172B2-patent-drawing

9. Origin of reduced efficiency in GaN-based micro-LEDs studied by scanning near-field optical microscopy

rinat yapparov, matthew s wong, tanay tak - American Institute of Physics, 2025

The quantum efficiency of micro-light emitting diodes (micro-LEDs) is lower than that large area LEDs. This reduction typically attributed to the nonradiative ShockleyReadHall recombination at surface defects and current leakage through sidewall region without a clear distinction between these effects. In this work, we attempt find out which phenomena most critical for reduced micro-LEDs. has been done by mapping electroluminescence (EL) photoluminescence (PL) measuring PL dynamics in blue GaN micro-LEDs fabricated dry etching. It found as-etched device, EL intensity much devices with KOH etching atomic layer deposition SiO2. effect especially pronounced close sidewalls. On other hand, decay times are similar passivated devices, both their center allows concluding main mechanism not recombination. be efficient means eliminate leakage.

10. Monolithic Micro LED Display Element with Flip-Chip Mount and Absorbing Structure

TOYODA GOSEI CO LTD, 2025

Flip-chip mounted monolithic micro LED display element with improved contrast. The element has a substrate, n-type, light-emitting, and p-type layers. Each light-emitting part has a first electrode on the p-type layer. An absorbing structure is above the first electrode with alternating dielectric and metal layers. A through hole connects the absorbing structure to a second electrode above. This prevents light transmission between pixels and reduces reflection/contrast loss.

US12300770B2-patent-drawing

11. Display Substrate with Light Dimming and Fixing Layers for MicroLED Arrays

BOE TECHNOLOGY GROUP CO LTD, BOE MLED TECHNOLOGY CO LTD, 2025

A display substrate design with improved contrast, light mixing reduction, and device fixation for microLED displays. The display substrate has a first light dimming layer between groups of microLEDs that absorbs external light and emitted light to improve contrast and prevent light mixing. A first fixing layer on the microLED side absorbs light and fixes the microLEDs to prevent falling. The light dimming and fixing layers are formed using inkjet printing.

US12300775B2-patent-drawing

12. Color Conversion Substrate with Overlapping Layer Light Blocking Structure

SAMSUNG DISPLAY CO LTD, 2025

Color conversion substrate for displays that prevents or reduces side light leakage. The substrate has a base with display area and peripheral area. A color filter is in the display area. A front light blocking member with overlapping colored layers is in the peripheral area. A side light blocking member outside the front member surrounds it. The side blocking member has overlapping colored layers. This effectively traps light from the front blocking member to prevent side light leakage.

US12302733B2-patent-drawing

13. Display Device with Grooved Substrate for Reduced Light Reflection in Transmission Areas

SAMSUNG DISPLAY CO LTD, 2025

Display device with reduced light reflection from transmission areas to improve image quality. The display has a substrate with grooves corresponding to the transmission areas. This reduces diffraction and reflection of light passing through the transmission areas compared to a plain substrate. The grooves can have varying widths to constructively interfere with light passing through protrusions on the substrate. This constructive interference reduces light loss as it travels from the display elements to the substrate and back.

US12302697B2-patent-drawing

14. Display Device with Stacked Insulation Layers Featuring Selective Openings and Refractive Index Variation

SAMSUNG DISPLAY CO LTD, 2025

Display device with improved light extraction efficiency and display quality by optimizing the internal structure around the pixels. The display has multiple color subpixels (RGB) on a substrate. Insulation layers are stacked above the subpixels. The lower insulation layer has openings overlapping some subpixels. A higher refractive index upper insulation layer is filled in these openings. This prevents light reflection at the interface between the two insulation layers. The openings are placed strategically to avoid overlapping some subpixels. This prevents light trapping when exiting the display. By selectively modifying the insulation layer stack around some subpixels, overall light extraction is increased while preserving color accuracy.

US12302699B2-patent-drawing

15. MicroLED Structure with Extended Active Layer Beyond Electrode Edges for Enhanced Light Extraction and Uniformity

JADE BIRD DISPLAY LTD, 2025

MicroLED structure and chip design that enables efficient manufacturing of microLED displays with reduced yield loss and improved uniformity. The microLED design involves extending the active light emitting layer beyond the edges of the top and bottom electrodes. This prevents the active layer from being completely covered by the electrodes, allowing the emitted light to spread out horizontally. The electrode edges align vertically to maintain contact, but the active layer extends laterally. This prevents light confinement and improves extraction efficiency. Sharing the active layer between multiple microLEDs also reduces variations in material quality and thickness. Isolation structures between microLEDs can be formed in the shared active layer to prevent light crosstalk.

16. Display Panel Cutting Method with Offset Substrate Lines for Reduced Edge Light Leakage

FUZHOU BOE OPTOELECTRONICS TECHNOLOGY CO LTD, BOE TECHNOLOGY GROUP CO LTD, 2025

Cutting a display panel to reduce light leakage at the edges and eliminate white borders or bright borders. The cutting method involves cutting the color-film substrate along a first line and the array substrate along a second line, with the second line moved inward by a preset distance relative to the first line. This reduces the exposed area of the array substrate edge if there are cutting errors, preventing light leakage from metal parts.

US12290950B2-patent-drawing

17. Display Panel with Block-Patterned Light-Transmitting Regions and Varying Structural Attributes

SHANGHAI TIANMA MICRO-ELECTRONICS CO LTD, 2025

A display panel and display device with reduced diffraction in transparent regions to improve display quality. The display panel has light-transmitting regions arranged in a block pattern with adjacent regions of different types. This prevents clustering of identical regions that can cause diffraction. The block layout with varying regions reduces diffraction artifacts when viewing objects through the transparent panel. The panel can have multiple blocks with varying arrangements in rows and columns. The blocks can also have different thicknesses, materials, or sub-film layers.

18. LED Display Pixels with Integrated Polarizers and Opaque Side Walls

THOMAS R JORY, 2025

LED displays with integrated polarizers in each pixel to improve contrast and eliminate the need for external polarizing films. The LED packages have a light polarizer directly integrated into the pixel, surrounded by an opaque side wall. This reduces stray light between pixels compared to external polarizers. The polarizer can be a linear polarizer with a quarter wave plate to circularly polarize the light. The integrated polarizers are formed by adding layers and cutting between pixels.

US2025143039A1-patent-drawing

19. Centralized Control System for Dynamic Adjustment of Photoelectric Parameters in Micro LED Transparent Screens

SICHUAN HUALING PHOTONICS TECH CO LTD, SICHUAN HUALING PHOTONICS TECHNOLOGY CO LTD, 2023

Intelligently adjusting photoelectric parameters of Micro LED transparent screens to improve display quality and efficiency. The method involves using a central processor to communicate with the individual RGB light source modules on the screen. By intelligently adjusting parameters like brightness, color, and power consumption of each module, it balances uniformity, contrast, and efficiency across the screen. This mitigates issues like brightness non-uniformity, outdoor visibility, cost, and power dissipation in Micro LED transparent displays.

CN117275363A-patent-drawing

20. Segmented LED Arrays with Integrated Diffusing Elements and Inter-segment Walls

Lumileds LLC, 2022

Segmented LED arrays with diffusing elements to improve uniformity and reduce patterns when using secondary optics. The arrays have LED segments separated by walls. Diffuser material is placed directly over the LEDs or wavelength converter to scatter light before it reaches secondary optics like lenses. This avoids patterns when using focus techniques. The diffuser can be columns, domes, or a continuous layer over multiple LEDs.

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