This relates generally to electronic devices, and, more particularly, to electronic devices with displays.
Electronic devices often include displays. For example, an electronic device may have an organic light-emitting diode (OLED) display based on organic light-emitting diode pixels or a liquid crystal display (LCD) based on liquid crystal display pixels. The display may include display driver circuitry that is configured to provide display data to the pixels and gate driver circuitry that is configured to control the pixels.
It is within this context that the embodiments herein arise.
An electronic device may include a substrate, an array of display pixels formed on the substrate, first conductive contacts on the substrate, second conductive contacts on the substrate, a flexible printed circuit that is attached to the first conductive contacts, a display driver integrated circuit that is attached to the second conductive contacts, conductive traces that electrically connect the first conductive contacts to the second conductive contacts, and a dielectric layer that at least partially covers the conductive traces. At least one trench may be formed in the dielectric layer that separates the dielectric layer into discrete portions separated by gaps.
An electronic device may include a substrate, a conductive trace on the substrate, and an organic dielectric layer that at least partially covers the conductive trace. At least one trench may be formed in the organic dielectric layer that divides the organic dielectric layer into discrete portions separated by at least one gap.
A method may include forming a conductive trace with sidewalls on a substrate, forming, along the length of the conductive trace, a dielectric layer over at least the sidewalls of the conductive trace, exposing the conductive trace and the dielectric layer to an etchant, and after exposing the conductive trace and the dielectric layer to the etchant, removing at least some of the dielectric layer.
An illustrative electronic device of the type that may be provided with a display is shown in
As shown in
Input-output circuitry in device 10 such as input-output devices 12 may be used to allow data to be supplied to device 10 and to allow data to be provided from device 10 to external devices. Input-output devices 12 may include buttons, joysticks, scrolling wheels, touch pads, key pads, keyboards, microphones, speakers, tone generators, vibrators, cameras, sensors, light-emitting diodes and other status indicators, data ports, etc. A user can control the operation of device 10 by supplying commands through input resources of input-output devices 12 and may receive status information and other output from device 10 using the output resources of input-output devices 12.
Input-output devices 12 may include one or more displays such as display 14. Display 14 may be a touch screen display that includes a touch sensor for gathering touch input from a user or display 14 may be insensitive to touch. A touch sensor for display 14 may be based on an array of capacitive touch sensor electrodes, acoustic touch sensor structures, resistive touch components, force-based touch sensor structures, a light-based touch sensor, or other suitable touch sensor arrangements. A touch sensor for display 14 may be formed from electrodes formed on a common display substrate with the display pixels of display 14 or may be formed from a separate touch sensor panel that overlaps the pixels of display 14. If desired, display 14 may be insensitive to touch (i.e., the touch sensor may be omitted). Display 14 in electronic device 10 may be a head-up display that can be viewed without requiring users to look away from a typical viewpoint or may be a head-mounted display that is incorporated into a device that is worn on a user's head. If desired, display 14 may also be a holographic display used to display holograms.
Control circuitry 16 may be used to run software on device 10 such as operating system code and applications. During operation of device 10, the software running on control circuitry 16 may display images on display 14.
Display 14 may have an array of pixels 22 for displaying images for a user such as pixel array 28. Pixels 22 in array 28 may be arranged in rows and columns. The edges of array 28 may be straight or curved (i.e., each row of pixels 22 and/or each column of pixels 22 in array 28 may have the same length or may have a different length). There may be any suitable number of rows and columns in array 28 (e.g., ten or more, one hundred or more, or one thousand or more, etc.). Display 14 may include pixels 22 of different colors. As an example, display 14 may include red pixels, green pixels, and blue pixels. Pixels of other colors such as cyan, magenta, and yellow might also be used.
Display driver circuitry 20 may be used to control the operation of pixels 28. Display driver circuitry 20 may be formed from integrated circuits, thin-film transistor circuits, and/or other suitable circuitry. Illustrative display driver circuitry 20 of
As shown in
To display the images on pixels 22, display driver circuitry 20A may supply corresponding image data to data lines D while issuing control signals to supporting display driver circuitry such as gate driver circuitry 20B over signal paths 30. With the illustrative arrangement of
Gate driver circuitry 20B (sometimes referred to as gate line driver circuitry or horizontal control signal circuitry) may be implemented using one or more integrated circuits and/or may be implemented using thin-film transistor circuitry on substrate 26. Horizontal control lines G (sometimes referred to as gate lines, scan lines, emission control lines, etc.) run horizontally across display 14. Each gate line G is associated with a respective row of pixels 22. If desired, there may be multiple horizontal control lines such as gate lines G associated with each row of pixels. Individually controlled and/or global signal paths in display 14 may also be used to distribute other signals (e.g., power supply signals, etc.).
Gate driver circuitry 20B may assert control signals on the gate lines G in display 14. For example, gate driver circuitry 20B may receive clock signals and other control signals from circuitry 20A on paths 30 and may, in response to the received signals, assert a gate line signal on gate lines G in sequence, starting with the gate line signal G in the first row of pixels 22 in array 28. As each gate line is asserted, data from data lines D may be loaded into a corresponding row of pixels. In this way, control circuitry such as display driver circuitry 20A and 20B may provide pixels 22 with signals that direct pixels 22 to display a desired image on display 14. Each pixel 22 may have a light-emitting diode and circuitry (e.g., thin-film circuitry on substrate 26) that responds to the control and data signals from display driver circuitry 20.
Gate driver circuitry 20B may include blocks of gate driver circuitry such as gate driver row blocks. Each gate driver row block may include circuitry such output buffers and other output driver circuitry, register circuits (e.g., registers that can be chained together to form a shift register), and signal lines, power lines, and other interconnects. Each gate driver row block may supply one or more gate signals to one or more respective gate lines in a corresponding row of the pixels of the array of pixels in the active area of display 14.
In the example of
As shown in
Display driver integrated circuit 50 may receive signals from flexible printed circuit 60. The flexible printed circuit 60 may be coupled between substrate layer 26 and printed circuit board 74. Flexible printed circuit 60 may be formed from one or more dielectric layers formed from a flexible material such as polyimide. Metal traces may be printed on the one or more dielectric layers. Printed circuit board 74 may be, for example, a rigid printed circuit board (sometimes referred to as a motherboard).
Flexible printed circuit 60 includes one or more contacts 62 (sometimes referred to as contact pads 62) and one or more contacts 68 (sometimes referred to as contact pads 68). Contacts 62 are electrically connected to a respective contact 66 (sometimes referred to as contact pads 66 or bond pads 66) in substrate 26 by conductive bonding structures 64 (sometimes referred to as conductive interconnect structures 64, conductive attachment structures 64, etc.). Contacts 68 are electrically connected to a respective contact 72 (sometimes referred to as contact pads 72 or bond pads 72) in rigid printed circuit board 74 by conductive bonding structures 70 (sometimes referred to as conductive interconnect structures 70, conductive attachment structures 70, etc.). Conductive bonding structures 64 and 70 may be, for example, formed from anisotropic conductive films and/or solder. A conductive bonding structure 64 is interposed between each respective contact 62 and contact 66. The conductive bonding structures 64 may form a physical and electrical connection between flexible printed circuit 60 and substrate 26. A conductive bonding structure 70 is interposed between each respective contact 68 and contact 72. The conductive bonding structures 70 may form a physical and electrical connection between flexible printed circuit 60 and rigid printed circuit board 74.
One or more conductive traces 78 (sometimes referred to herein as traces 78, metal traces 78, connection traces 78, etc.) may be formed on substrate 26 between contacts 66 and contacts 56. In other words, the conductive traces 78 provide one or more paths for signals from flexible printed circuit 60 (at contacts 66) to be provided to display driver integrated circuit 50 (at contacts 56). Each conductive trace 78 may be electrically connected between at least one contact 66 at a first end and at least one contact 56 at a second end.
During operations of the electronic device of
If care is not taken, traces 78 between contacts 66 (that are electrically connected to the flexible printed circuit) and contacts 56 (that are electrically connected to the display driver integrated circuit) may not be as robust as desired.
A method for forming traces 78 is shown in
As shown at step 106, exposure of traces 78 (and particularly the sidewalls of traces 78) to etchant 82 may cause damage such as undercuts (voids) in the sidewalls of traces 78. This damage to traces 78 may reduce the reliability of traces 78 during subsequent operations of display 14.
Moreover, exposure of traces 78 (and particularly the sidewalls of traces 78) to etchant 82 may cause undesirable particle generation. For example, particles originating from traces 78 such as silver particles may cause visible artifacts (e.g., perceptible black dots) during subsequent operations of display 14.
To mitigate the aforementioned issues associated with exposure of traces 78 (and particularly the sidewalls of traces 78) to etchant 82, a protective dielectric layer may cover at least the sidewalls of traces 78 when the traces are exposed to the etchant. A method of this type is shown in
First, at step 112, traces 78 may be formed on substrate 26 (e.g., using any desired deposition and/or patterning steps). Next, at step 114, a protective dielectric layer 86 (sometimes referred to as cladding 86, cladding layer 86, protective layer 86, dielectric layer 86, planarization layer 86, organic layer 86, organic dielectric layer 86, organic planarization layer 86, etc.) is formed between traces 78. As shown in
After cladding 86 is covering the sidewalls of traces 78, the etching step is performed at step 116 (similar to as in step 104 of
Including cladding 86 to cover the sidewalls of traces 78 therefore mitigates reliability issues associated with exposure of traces 78 (and particularly the sidewalls of traces 78) to etchant 82.
Although cladding layer 86 desirably mitigates damage to traces 78 during manufacturing, the cladding layer may undesirably provide a moisture ingress path that can cause damage to traces 78. As shown in
To mitigate reliability issues associated with moisture ingress into cladding layer 86, some or all of cladding layer 86 may be removed in trace region 88 after the cladding layer 86 has been used to protect traces 78 from damage during etching.
After cladding 86 is covering the sidewalls of traces 78, the etching step is performed at step 126 (similar to as in step 116 of
At step 128, some or all of cladding layer 86 may be removed (once the etching of step 126 is complete and etchant 82 is no longer present). As shown in
After the plasma ashing is complete, as shown at step 130, traces 78 are present on substrate 26 and do not have sidewall damage/voids. Moreover, the cladding layer 86 is no longer present, preventing moisture ingress in the trace region through the cladding layer.
Removing cladding 86 after the cladding has protected the traces 78 during etching therefore mitigates both the reliability issues associated with exposure of traces 78 to etchant 82 and the reliability issues associated with moisture ingress through cladding 86.
In another example, shown in
As shown in
In
Each trench 96 may be interposed between contacts 66 and contacts 56 such that contacts 56 are formed on a first side of the trench and contacts 66 are formed on a second, opposing side of the trench.
Each trace 78 may extend in a first direction between contacts 66 and contacts 56. Each trench may extend in a second direction that is non-parallel to the first direction. The second direction may be orthogonal to the first direction (as in
In
In connection with
The foregoing is merely illustrative and various modifications can be made by those skilled in the art without departing from the scope and spirit of the described embodiments. The foregoing embodiments may be implemented individually or in any combination.
This application claims priority to U.S. provisional patent application No. 63/493,970 filed Apr. 3, 2023, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | |
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63493970 | Apr 2023 | US |