The present disclosure relates to the field of lighting and display technologies, and in particular, to a wiring board and a manufacturing method thereof, and a functional backplane.
Compared with an organic light-emitting diode (OLED) light-emitting device, in a light-emitting diode (LED), an inorganic semiconductor material is used to manufacture a PN junction, and carriers are combined in the PN junction to realize light emission under a drive of an electric field, so that a light-emitting brightness and a response speed are higher.
In an aspect, a wiring board is provided. The wiring board includes a mother board and a daughter board that are stacked, a bonding layer disposed between the mother board and the daughter board, and at least one side wiring. The mother board includes a first substrate and a first wiring layer disposed on the first substrate, and the first wiring layer includes at least one first connection pad. The daughter board is disposed on a side of the first substrate away from the first wiring layer. The daughter board includes a second substrate and a second wiring layer disposed on the second substrate, and the second wiring layer includes at least one second connection pad. The at least one side wiring is connected, via a respective end thereof, to the at least one first connection pad in one-to-one correspondence, and the at least one side wiring is connected, via respective another end thereof, to the at least one second connection pad in one-to-one correspondence.
In some embodiments, the second wiring layer is disposed on a side of the second substrate proximate to the mother board. At least one first via is disposed in the second substrate, and each first via exposes a portion of the second wiring layer that constitutes a second connection pad in the at least one second connection pad.
Alternatively, the second wiring layer includes a first sub-layer and a second sub-layer that are respectively disposed on two opposite sides of the second substrate in a thickness direction of the second substrate, and the first sub-layer is closer to the mother board than the second sub-layer. The second sub-layer includes the at least one second connection pad. At least one second via is disposed in the second substrate, and a second connection pad in the at least one second connection pad is electrically connected to the first sub-layer through a second via in the at least one second via. Alternatively, the second wiring layer is disposed on a side of the second substrate away from the mother board. The daughter board further includes an insulating layer disposed on a side of the second wiring layer away from the second substrate. At least one sixth via is disposed in the insulating layer, and each sixth via exposes a portion of the second wiring layer that constitutes a second connection pad in the at least one second connection pad.
In some embodiments, in a case where the second wiring layer includes the first sub-layer and the second sub-layer, an orthographic projection of edges of each second connection pad on the second substrate exceeds an orthographic projection, on the second substrate, of an edge of a corresponding second via proximate to this second connection pad.
In some embodiments, a distance between the orthographic projection of the edges of each second connection pad on the second substrate and the orthographic projection of the edge of the corresponding second via on the second substrate is in a range of 10 microns to 30 microns, inclusive.
In some embodiments, the second wiring layer further includes at least one fan-out wiring and at least one third connection pad. The at least one fan-out wiring is connected, via a respective end thereof, to the at least one third connection pad in one-to-one correspondence, and the at least one fan-out wiring is connected, via respective another end thereof, to the at least one second connection pad in one-to-one correspondence.
In some embodiments, in a case where the second wiring layer is disposed on the side of the second substrate proximate to the mother board, the at least one first via is disposed in the second substrate, and each first via exposes the portion of the second wiring layer that constitutes the second connection pad, the second wiring layer includes the at least one fan-out wiring. At least one third via is further disposed in the second substrate, and each third via exposes a portion of the second wiring layer that constitutes a third connection pad in the at least one third connection pad. The at least one first via is in one-to-one correspondence with the at least one third via, and a first via in the at least one first via and a corresponding third via in the at least one third via are located on a same fan-out wiring. In a case where the second wiring layer includes the first sub-layer and the second sub-layer, and the at least one second via is disposed in the second substrate, the first sub-layer includes the at least one fan-out wiring. The second sub-layer further includes the at least one third connection pad. At least one fourth via is further disposed in the second substrate, and each third connection pad is connected to a fan-out wiring in the at least one fan-out wiring through a fourth via in the at least one fourth via. The at least one fourth via is in one-to-one correspondence with the at least one second via, and a fourth via in the at least one fourth via and a corresponding second via in the at least one second via are located on a same fan-out wiring. In a case where the second wiring layer is disposed on the side of the second substrate away from the mother board, the daughter board further includes the insulating layer disposed on the side of the second wiring layer away from the second substrate, and the at least one sixth via is disposed in the insulating layer, the second wiring layer includes the at least one fan-out wiring. At least one fifth via is further disposed in the insulating layer, and each fifth via exposes a portion of the second wiring layer that constitutes a third connection pad in the at least one third connection pad. The at least one fifth via is in one-to-one correspondence with the at least one sixth via, and a fifth via in the at least one fifth via and a corresponding sixth via in the at least one sixth via are located on a same fan-out wiring.
In some embodiments, the mother board has an active area and a passive area located on a side of the active area. The at least one first connection pad is disposed in the passive area, the daughter board is arranged close to the passive area, and an orthographic projection of the daughter board on the first substrate does not exceed edges of the first substrate.
In some embodiments, the mother board has a shape of a rectangle. The active area and the passive area are arranged in sequence in a first direction, and the first direction is a direction represented by a long side or a short side of the rectangle. In a case where the first direction is the direction represented by the long side of the rectangle, the at least one side wiring is disposed on a side of the wiring board corresponding to the short side of the rectangle. In a case where the first direction is the direction represented by the short side of the rectangle, the at least one side wiring is disposed on a side of the wiring board corresponding to the long side of the rectangle.
In some embodiments, the at least one second connection pad is arranged close to the passive area; and the at least one first connection pad includes a plurality of first connection pads, and the at least one second connection pad includes a plurality of second connection pads. The plurality of first connection pads are arranged in sequence in a second direction, and the plurality of second connection pads are arranged in sequence in the second direction. Each first connection pad is in correspondence with a second connection pad in the plurality of second connection pads connected to this first connection pad in a thickness direction of the second substrate. The second direction is perpendicular to the first direction.
In some embodiments, the wiring board further includes a protective layer disposed on the at least one side wiring, and an orthographic projection of edges of the protective layer on the first substrate exceeds an orthographic projection of edges of the at least one side wiring on the first substrate.
In some embodiments, a distance between an edge of the protective layer and a corresponding edge of an entirety of the at least one side wiring is greater than or equal to 20 microns.
In some embodiments, in a case where the active area and the passive area are arranged in sequence in the first direction, and the first direction is the direction represented by the long side of the rectangle, there is a first gap between an orthographic projection, on the first substrate, of an edge of the daughter board proximate to the passive area and an edge of the first substrate corresponding to the short side of the rectangle and the edge of the daughter board. The wiring board further includes a first level difference filling layer, and the first level difference filling layer is disposed between the daughter board and the at least one side wiring, and is located in the first gap. In a case where the active area and the passive area are arranged in sequence in the first direction, and the first direction is the direction represented by the short side of the rectangle, there is a second gap between the orthographic projection, on the first substrate, of the edge of the daughter board proximate to the passive area and an edge of the first substrate corresponding to the long side of the rectangle and the edge of the daughter board. The wiring board further includes a second level difference filling layer, and the second level difference filling layer is disposed between the daughter board and the at least one side wiring, and is located in the second gap.
In some embodiments, in a case where the wiring board includes the first level difference filling layer, a surface of the first level difference filling layer opposite to the side of the wiring board where the at least one side wiring is located is an arc-shaped surface; in a case where the wiring board includes the second level difference filling layer, a surface of the second level difference filling layer opposite to the side of the wiring board where the at least one side wiring is located is an arc-shaped surface.
In some embodiments, a chamfer structure or a rounded corner structure is disposed at a position of the first substrate corresponding to a side of the wiring board where the at least one side wiring is located.
In some embodiments, a thickness of the bonding layer is in a range of 8 microns to 15 microns, inclusive, and a thickness of the second substrate is in a range of 5 microns to 20 microns, inclusive.
In some embodiments, in a case where the second wiring layer is disposed on the side of the second substrate proximate to the mother board, or is disposed on the side of the second substrate away from the mother board, a thickness of the second wiring layer is in a range of 0.6 microns to 2 microns, inclusive. In a case where the second wiring layer includes the first sub-layer and the second sub-layer, a thickness of the first sub-layer and a thickness of the second sub-layer are each in a range of 0.6 microns to 2 microns, inclusive.
In another aspect, a functional backplane is provided. The functional backplane includes the above wiring board and at least one electronic element. The at least one electronic element is disposed on the wiring board, and is electrically connected to the first wiring layer in the wiring board.
In yet another aspect, a manufacturing method of a wiring board is provided. The manufacturing method of the wiring board includes following steps.
A mother board and a daughter board are manufactured separately. The mother board includes a first substrate and a first wiring layer formed on the first substrate, and the first wiring layer includes at least one first connection pad. The daughter board includes a second substrate and a second wiring layer formed on the second substrate, and the second wiring layer includes at least one second connection pad.
A bonding layer is formed between the mother board and the daughter board to connect the mother board and the daughter board. The daughter board is formed on a side of the first substrate away from the first wiring layer.
At least one side wiring is formed on the mother board and the daughter board. The at least one side wiring is connected, via a respective end thereof, to the at least one first connection pad in one-to-one correspondence, and the at least one side wiring is connected, via respective another end thereof, to the at least one second connection pad in one-to-one correspondence.
In some embodiments, the second substrate is a flexible substrate. Manufacturing the daughter board, includes following steps.
A sacrificial layer is formed on a third substrate.
The at least one second connection pad is formed on the third substrate on which the sacrificial layer is formed.
A flexible film is formed on the third substrate on which the at least one second connection pad is formed, and at least one second via is formed in the flexible film. Each second via corresponds to a second connection pad in the at least one second connection pad.
A third wiring layer is formed on the third substrate on which the at least one second via is formed. Each second connection pad is electrically connected to the third wiring layer through a second via in the at least one second via.
The sacrificial layer is heated or irradiated with light to separate the second substrate and the at least one second connection pad from the third substrate, so as to obtain the daughter board.
In some embodiments, the second substrate is a rigid substrate. Manufacturing the daughter board, includes a following step.
The second wiring layer is directly formed on the second substrate to obtain the daughter board.
In some embodiments, a material of the bonding layer includes an adhesive. Before the sacrificial layer is heated or irradiated with light to separate the second substrate and the at least one second connection pad from the third substrate, manufacturing the daughter board further includes: sequentially forming a glue layer and a release layer on the third substrate on which the third wiring layer is formed. After the sacrificial layer is heated or irradiated with light to separate the second substrate and the at least one second connection pad from the third substrate, the manufacturing method of the wiring board further includes: removing the release layer to expose the glue layer, so as to adhere the mother board to the daughter board by using the glue layer.
In order to describe technical solutions in the present disclosure more clearly, accompanying drawings to be used in some embodiments of the present disclosure will be introduced briefly below. Obviously, the accompanying drawings to be described below are merely accompanying drawings of some embodiments of the present disclosure, and a person of ordinary skill in the art may obtain other drawings according to these drawings. In addition, the accompanying drawings to be described below may be regarded as schematic diagrams, and are not limitations on an actual size of a product, an actual process of a method and an actual timing of a signal involved in the embodiments of the present disclosure.
Technical solutions in some embodiments of the present disclosure will be described clearly and completely below with reference to the accompanying drawings. Obviously, the described embodiments are merely some but not all embodiments of the present disclosure. All other embodiments obtained by a person of ordinary skill in the art based on the embodiments of the present disclosure shall be included in the protection scope of the present disclosure.
Unless the context requires otherwise, throughout the description and the claims, the term “comprise” and other forms thereof such as the third-person singular form “comprises” and the present participle form “comprising” are construed as an open and inclusive meaning, i.e., “including, but not limited to.” In the description of the specification, the terms such as “one embodiment,” “some embodiments,” “exemplary embodiments,” “an example,” “specific example” or “some examples” are intended to indicate that specific features, structures, materials or characteristics related to the embodiment(s) or example(s) are included in at least one embodiment or example of the present disclosure. Schematic representations of the above terms do not necessarily refer to the same embodiment(s) or example(s). In addition, the specific features, structures, materials or characteristics may be included in any one or more embodiments or examples in any suitable manner.
Hereinafter, the terms such as “first” and “second” are only used for descriptive purposes, and are not to be construed as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Thus, a feature defined with “first” or “second” may explicitly or implicitly include one or more of the features. In the description of the embodiments of the present disclosure, the term “a plurality of/the plurality of” means two or more unless otherwise specified.
The phrase “at least one of A, B and C” has the same meaning as the phrase “at least one of A, B or C”, both including following combinations of A, B and C: only A, only B, only C, a combination of A and B, a combination of A and C, a combination of B and C, and a combination of A, B and C.
The phrase “A and/or B” includes following three combinations: only A, only B, and a combination of A and B.
The use of the phase “applicable to” or “configured to” herein means an open and inclusive expression, which does not exclude devices that are applicable to or configured to perform additional tasks or steps.
Some embodiments of the present disclosure provide a light-emitting apparatus. The light-emitting apparatus includes a functional backplane. Of course, the light-emitting apparatus may further include other components, such as a circuit for providing electrical signals to the functional backplane to drive the functional backplane to emit light. The circuit may be referred to as a control circuit, and may include a circuit board and/or an integrated circuit (IC) electrically connected to the functional backplane.
In some embodiments, the light-emitting apparatus may be a lighting apparatus, and in this case, the light-emitting apparatus is used as a light source to realize a lighting function. For example, the light-emitting apparatus may be a backlight module in a liquid crystal display apparatus, a lamp for internal or external lighting, or a signal lamp.
In some other embodiments, the light-emitting apparatus may be a display apparatus, and in this case, the functional backplane is a display substrate for realizing a function of displaying an image (i.e., picture). The light-emitting apparatus may include a display or a product including a display. The display may be a flat panel display (FPD), or a microdisplay. The display may be a transparent display or an opaque display, depending on whether a user can see a scene behind the display. The display may be a flexible display or a normal display (which may be referred to as a rigid display), depending on whether the display is bendable or rollable. For example, the product including the display may be a computer display, a television, a billboard, a laser printer with a display function, a telephone, a mobile phone, a personal digital assistant (PDA), a laptop computer, a digital camera, a camcorder, a viewfinder, a vehicle, a large area wall screen, a theater screen, or a stadium sign.
Some embodiments of the present disclosure provide the functional backplane. As shown in
In some embodiments, in an example where the electronic element 20 is the micro light-emitting diode, the functional backplane 100 may be used as a backlight source or a display apparatus. In a case where the functional backplane 100 is used as the backlight source, a passive display panel (e.g., a liquid crystal display panel) may be matched with the functional backplane 100 to display a full color picture. In this case, the functional backplane 100 may integrally emit monochromatic light or polychromatic light (e.g., white light), and by arranging a plurality of micro light-emitting diodes in a matrix and combining a local dimming technology, a fine brightness control and a high color contrast may be achieved. In a case where the functional backplane 100 is used as the display apparatus, the functional backplane 100 may be provided with micro light-emitting diodes capable of emitting light of different colors, which cooperate with each other to display a full color picture, so that the functional backplane 100 may have a high brightness and a high contrast.
At present, considering a process yield and a manufacturing cost, when a large-size product is manufactured, a plurality of functional backplanes may be spliced. In order to avoid influencing a user experience due to a split feeling possibly generated by splicing between adjacent functional backplanes, a functional backplane is designed to have an ultra-narrow bezel or even have no bezel to achieve a seamless splicing effect. This method is a development direction in the field.
In order to realize an ultra-narrow bezel display, as shown in
Based on this, some embodiments of the present disclosure provide the wiring board 10. As shown in
The mother board 1 includes a first substrate 11 and a first wiring layer 12 disposed on the first substrate 11. The first wiring layer 12 includes driving element(s) 121 connected to the electronic element(s) 20, and at least one first connection pad 122. As shown in
In some embodiments, as shown in
In these embodiments, the at least one first connection pad 122 is connected to the at least one second connection pad 221 in one-to-one correspondence through the at least one side wiring 4. That is, the at least one second connection pad 221 may transmit driving signal(s) to the at least one first connection pad 122, thereby transmitting the driving signal(s) to the driving element(s) 121.
The bonding layer 3 is a film layer that is disposed between the mother board 1 and the daughter board 2 and is capable of being bonded to the mother board 1 and the daughter board 2. For example, in some embodiments, the bonding layer 3 may be made of, an adhesive glue or an adhesive.
In the embodiments of the present disclosure, by providing the first substrate 11 and the second substrate 21, the first wiring layer 12 may be manufactured on the first substrate 11, and the second wiring layer 22 may be manufactured on the second substrate 21, so that the scratching problem may be avoided to ensure and improve the manufacturing yield, thereby reducing the production cost, compared with the related art in which the wiring(s) are directly disposed on the two opposite surfaces of the substrate S (e.g., the first substrate 11) of the wiring board 10′ as shown in
A structure and an arrangement of the second wiring layer 22 are not specifically limited.
In some embodiments, the second wiring layer 22 may be have single-layer structure or a multi-layer structure. In a case where the second wiring layer 22 has the single-layer structure, the second wiring layer 22 may be disposed on a side of the second substrate 21 proximate to the mother board 1, or disposed on a side of the second substrate 21 away from the mother board 1; in a case where the second wiring layer 22 has the multi-layer structure, the multi-layer structure may be disposed on the side of the second substrate 21 proximate to the mother board 1, or disposed on the side of the second substrate 21 away from the mother board 1, which is not specifically limited here.
In some embodiments, as shown in
In these embodiments, since the second wiring layer 22 is disposed on the side of the second substrate 21 proximate to the mother board 1, the second wiring layer 22 may be hidden under the second substrate 21, so that the second wiring layer 22 may be further prevented from being scratched.
A material of the second substrate 21 may be selected from organic materials such as polyimide and polymethyl methacrylate.
During manufacturing, a sacrificial layer, the second wiring layer 22 and the second substrate 21 may be sequentially formed on a rigid substrate. In a case where the second wiring layer 22 has a strong adhesion to the second substrate 21, the second substrate 21 on which the second wiring layer 22 is formed may be obtained by peeling.
In order to increase the adhesion of the second wiring layer 22 to the second substrate 21, the mother board further includes a buffer layer 24 disposed between the second wiring layer 22 and the second substrate 21. The buffer layer 24 may be made of silicon oxide (e.g., SiO), silicon nitride (e.g., SiN), or silicon oxynitride (e.g., SiON). In addition to increasing the adhesion of the second wiring layer 22 to the second substrate 21, the buffer layer 24 may function to isolate water and oxygen.
In some other embodiments, as shown in
In these embodiments, the second wiring layer 22 has the multi-layer structure, and the second via(s) K2 are disposed in the second substrate 21, so that the first sub-layer 22a is electrically connected to the second connection pad(s) 221. Moreover, in these embodiments, the first sub-layer 22a may have the same structure as that of the second wiring layer 22 with the single-layer structure, and the first sub-layer 22a may also be disposed on the side of the second substrate 21 towards the mother board, so that the second wiring layer 22 is able to be further prevented from being scratched.
It will be noted that unlike the second wiring layer 22 disposed on the side of the second substrate 21 proximate to the mother board, the second wiring layer 22 includes the first sub-layer 22a and the second sub-layer 22b, the first sub-layer 22a is located on the side of the second substrate 21 proximate to the mother board, and the second sub- layer 22b is located on the side of the second substrate 21 away from the mother board.
Based on this, in some embodiments, as shown in
In these embodiments, a contact area of the second connection pad 221 and the second substrate 21 may be increased, so that the second connection pad 221 is able to be prevented from falling off.
A material of the second substrate 21 may be selected from organic materials such as polyimide and polymethyl methacrylate.
During manufacturing, a sacrificial layer, the second sub-layer 22b, the second substrate 21 and the first sub-layer 22a may be sequentially formed on a rigid substrate. Then, the second substrate 21 on which the second wiring layer 22 is formed may be obtained by peeling.
In this process, since the orthographic projection of the edges of each second connection pad 221 on the second substrate 21 exceeds the orthographic projection, on the second substrate 21, of the edge of the corresponding second via K2 proximate to this second connection pad 221, the subsequent peeling is facilitated by increasing the contact area of the second connection pad 221 and the second substrate.
For example, in some embodiments, as shown in
In these embodiments, by limiting the distance g1 between the orthographic projection of the edges of each second connection pad 221 on the second substrate 21 and the orthographic projection, on the second substrate 21, of the edge of the corresponding second via K2 to the range of 10 microns to 30 microns, a success rate of the peeling may be improved to a maximum extent while ensuring a small coverage area of the second sub-layer 22b.
In some embodiments, as shown in
In order to increase the adhesion of the first sub-layer 22a to the second substrate 21, the daughter board further includes a buffer layer 24 disposed between the first sub-layer 22a and the second substrate 21. The buffer layer 24 may be made of silicon oxide (e.g., SiO), silicon nitride (e.g., SiN), or silicon oxynitride (e.g., SiON). In addition to increasing the adhesion of the first sub-layer 22a to the second substrate 21, the buffer layer 24 may function to isolate water and oxygen.
In yet other embodiments, as shown in
In these embodiments, the second wiring layer 22 may be hidden under the insulating layer 23, so that the second wiring layer 22 is also able to be prevented from being scratched.
The insulating layer 23 may include an inorganic insulating layer and an organic insulating layer stacked in sequence in a direction away from the mother board 1.
The inorganic insulating layer may be made of silicon oxide (e.g., SiO), silicon nitride (e.g., SiN), or silicon oxynitride (e.g., SiON), and the inorganic insulating layer may function to isolate water and oxygen. The organic insulating layer may be made of a resin material (e.g., epoxy resin), and the organic insulating layer may have a planarization function.
In some embodiments, the second substrate 21 may be a rigid substrate, such as a glass substrate. In this case, the second wiring layer 22 and the insulating layer 23 may be directly formed on the glass substrate obtain the daughter board. Then, the bonding layer 3 may be used to connect the mother board and the daughter board, thereby obtaining the wiring board.
In some other embodiments, a sacrificial layer, the second substrate 21, the second wiring layer 22 and the insulating layer 23 are sequentially formed on the rigid substrate. Then, the second substrate 21 on which the second wiring layer 22 is formed may be obtained by peeling the second substrate from the rigid substrate. In this case, the bonding layer 3 may be formed on a side of the second substrate 21 away from the second wiring layer 22, so that the second substrate 21 is connected to the mother board by the bonding layer 3.
In these embodiments, unlike the second substrate 21 which is the rigid substrate and on which the second wiring layer 22 is directly formed, the daughter board may further include a buffer layer disposed between the second wiring layer 22 and the second substrate 21. A material and a function of the buffer layer may refer to the above description, and will not be repeated here.
In some embodiments, as shown in
As shown in
As shown in
Structures of the at least one fan-out wiring 222 and the at least one third connection pad 223 are not specifically limited, as long as the at least one fan-out wiring 222 is connected, via its respective end, to the at least one third connection pad 223 in one-to-one correspondence, and the at least one fan-out wiring 222 is connected, via its respective another end, to the at least one second connection pad 221 in one-to-one correspondence.
In some embodiments, as shown in
In these embodiments, similar to the fact that the at least one first via K1 is disposed in the second substrate 21, the at least one third connection pad 223 may be formed by arranging the at least one third via K3 in the second substrate 21. Since the first via(s) K1 are in one-to-one correspondence with the third via(s) K3, and the first via K1 and the corresponding third via K3 are located on the same fan-out wiring 222, the at least one third connection pad 223 may be connected to the at least one second connection pad 221 in one-to-one correspondence through the at least one fan-out wiring 222.
In some other embodiments, as shown in
In these embodiments, similar to the fact that the at least one second via K2 is disposed in the second substrate 21, by arranging the at least one fourth via K4 in the second substrate 21, each third connection pad 223 is connected to a fan-out wiring 222 through a fourth via K4, the fourth via(s) K4 are in one-to-one correspondence with the second via(s) K2, and the fourth via K4 and the corresponding second via K2 are located on the same fan-out wiring 222. Moreover, each second connection pad 221 is connected to the first sub-layer 22a by a second via K2. Therefore, in a case where the first sub-layer 22a includes the at least one fan-out wiring 222, the at least one third connection pad 223 is connected to the at least one second connection pad 221 in one-to-one correspondence, and a third connection pad 223 is connected to a corresponding second connection pad 221 through a same fan-out wiring 222.
In yet other embodiments, as shown in
In these embodiments, similar to the case that the at least one sixth via K6 is disposed in the insulating layer 23, by arranging the at least one fifth via K5 in the insulating layer 23, each fifth via K5 exposes the portion of the second wiring layer 22 that constitutes the third connection pad 223, the fifth via(s) K5 are in one-to-one correspondence with the sixth via(s) K6, and the fifth via K5 and the corresponding sixth via K6 are located on the same fan-out wiring 222. Therefore, the third connection pad(s) 223 are in one-to-one correspondence with the second connection pad(s) 221, and a third connection pad 223 and a corresponding second connection pad 221 are located on a same fan-out wiring 222. That is, the second connection pad(s) 221 are electrically connected to the third connection pad(s) 223 in one-to-one correspondence, and a second connection pad 221 is electrically connected to a corresponding third connection pad 223 through a fan-out wiring 222.
A size and a position of the mother board 1, and a size and a position of the daughter board 2 are not specifically limited, as long as the mother board 1 and the daughter board 2 are stacked.
In some embodiments, as shown in
shape of a rectangle. The active area A and the passive area B are arranged in sequence in a first direction (indicated by the arrow a in
In these embodiments, as shown in
In addition, in some embodiments, in the case where the first direction is the direction represented by the long side of the rectangle, the first gap G1 is less than or equal to 50 microns. In the case where the first direction is the direction represented by the short side of the rectangular shape, the second gap G2 is less than or equal to 50 microns.
An extending direction of the at least one fan-out wiring 222 is not specifically limited, as long as two ends of each fan-out wiring 222 are respectively electrically connected to a third connection pad 223 and a second connection pad 221.
In some embodiments, as shown in
In these embodiments, as shown in
In some embodiments, as shown in
In these embodiments, the protective layer 6 may be made of, for example, an insulating material, such as silicon nitride (SiN) or epoxy resin, and may protect the at least one side wiring 4.
In some embodiments, a distance g2 between an edge of the protective layer 6 and a corresponding edge of an entirety of the at least one side wiring 4 is greater than or equal to 20 microns.
In these embodiments, by controlling the distance g2 between the edge of the protective layer 6 and the corresponding edge of the entirety of the at least one side wiring 4 to be greater than or equal to 20 microns, the protective layer 6 may be ensured to completely covers the at least one side wiring 4 to avoid an electric leakage.
In some embodiments, as shown in
In these embodiments, by arranging the first level difference filling layer 51 in the first gap G1, the first gap G1 may be filled to reduce a level difference at the first gap G1, so as to avoid a problem that the manufacturing of the side wiring(s) is not facilitated due to an excessive level difference. For example, the excessive level difference is not conducive to forming the at least one side wiring by using exposure and development methods. Alternatively, by arranging the second level difference filling layer in the second gap G2, the second gap G2 may be filled to reduce a level difference at the second gap G2, so as to avoid a problem that the manufacturing of the side wiring(s) is not facilitated due to an excessive level difference. For example, the excessive level difference is not conducive to forming the at least one side wiring 4 by using exposure and development methods.
In some embodiments, the first level difference filling layer 51 may be made of an organic material for planarizing the first gap G1, or the second level difference filling layer 52 may be made of an organic material for planarizing the second gap G2.
In some embodiments, as shown in
In these embodiments, a risk of wire breakage may be avoided by arranging the surface of the first level difference filling layer 51 opposite to the side of the wiring board 10 where the at least one side wiring 4 is located to be the arc-shaped surface, or by arranging the surface of the second level difference filling layer 52 opposite to the side of the wiring board 10 where the at least one side wiring 4 is located to be the arc-shaped surface.
Of course, in some embodiments, in order to reduce the level difference, thicknesses of the bonding layer 3 and the second substrate 21 may be thinned.
For example, in some embodiments, as shown in
In some embodiments, in the case where the second wiring layer 22 is disposed on the side of the second substrate 21 proximate to the mother board 1, or in the case where the second wiring layer 22 is disposed on the side of the second substrate 21 away from the mother board 1, a thickness of the second wiring layer 22 is in a range of 0.6 microns to 2 microns, inclusive.
In these embodiments, in the case where the second wiring layer 22 is disposed on the side of the second substrate 21 proximate to the mother board 1, or in the case where the second wiring layer 22 is disposed on the side of the second substrate 21 away from the mother board 1, the level difference may be further reduced by limiting the thickness of the second wiring layer 22 to the range of 0.6 microns to 2 microns. In some other embodiments, as shown in
wiring layer 22 includes the first sub-layer 22a and the second sub-layer 22b, the thickness d31 of the first sub-layer 22a and the thickness d32 of the second sub-layer 22b are each in a range of 0.6 microns to 2 microns.
In these embodiments, by limiting the thickness d31 of the first sub-layer 22a and the thickness d32 of the second sub-layer 22b to the above range, the level difference may also be further reduced.
In some embodiments, as shown in
In some embodiments, as shown in
In these embodiments, the risk of wire breakage may be avoided by arranging chamfer structure(s) or rounded corner structure(s) at a position of the first substrate 11 corresponding to the side of the wiring board 10 where the at least one side wiring 4 is located.
The specific structure of the wiring board 10 is described above. Hereinafter, a connection method of the wiring board 10 and the electronic element(s) 20, a structure of the first wiring layer 12, and a specific drive method of the functional backplane will be introduced.
In some embodiments, as shown in
In some embodiments, as shown in
In some embodiments, the plurality of fourth connection pads 123 may be divided into a plurality of fourth connection pad groups. Each fourth connection pad group is used to be connected to an electronic element 20, and includes a cathode bonding pad and an anode bonding pad arranged in pair. A fourth connection pad 123 soldered to the cathode pin of the electronic element 20 is referred to as a cathode bonding pad, and a fourth connection pad 123 soldered to the anode pin of the electronic element is referred to as an anode bonding pad.
A material of the first sub-metal layer 12a_1 and a material of the second sub-metal layer 12a_3 each include a molybdenum niobium alloy that has adhesion to enhance an adhesion force between the first routing layer 12a and the first substrate 11. In some cases, in order to prevent the first substrate 11 from being damaged due to an excessive stress caused by an excessive overall area of an orthographic projection of the first routing layer 12a on the first substrate 11, a buffer layer may be provided between the first substrate 11 and the first routing layer 12a to relieve the stress. In addition, the first sub-metal layer 12a_1 including the molybdenum niobium alloy may further enhance an adhesion force between the first routing layer 12a and the buffer layer. A material of the buffer layer may be, for example, silicon nitride. Moreover, the second sub-metal layer 12a_3 including the molybdenum niobium alloy is connected to the fourth connection pads 123, and since the molybdenum niobium alloy has adhesion, connection stability between the first routing layer 12a and the fourth connection pad 123 may be ensured; and since the molybdenum niobium alloy has conductivity, conductivity between the fourth connection pad 123 and the first routing layer 12a may be ensured. A material of the first sub-routing layer 12a_2 may include copper that has good conductivity, which may ensure electrical connections between film layers. Copper has a small resistance, which may reduce a current loss during operation, and copper has a low price, which may reduce the manufacturing cost of the functional backplane. In addition, the second sub-metal layer 12a_3 including the molybdenum niobium alloy may protect copper in the first sub-routing layer 12a_2 from being oxidized.
In some embodiments, as shown in
In some embodiments, as shown in
In some embodiments, as shown in
As shown in
In some embodiments, as shown in
In some embodiments, as shown in
In some embodiments, as shown in
In some embodiments, as shown in
The third planarization layer 143 and the first planarization layer 141 are arranged in the same layer, and may be of an integral structure. The third planarization layer 143 and the first planarization layer 141 may be made of an organic material (e.g., resin) for planarization, so as to facilitate manufacturing in a subsequent process (e.g., manufacturing of the fourth connection pads 123 and the first connection pad(s) 122). The fourth planarization layer 144 and the second planarization layer 142 are arranged in the same layer, and may be of an integral structure. The fourth planarization layer 144 and the second planarization layer 142 may be made of an organic material (e.g., resin) for planarization, so as to facilitate manufacturing in a subsequent process (e.g., manufacturing of the protective layer 16). The second passivation layer 132 and the first passivation layer 131 are arranged in the same layer, and may be of an integral structure. The second passivation layer 132 and the first passivation layer 131 may be made of silicon oxynitride, silicon nitride, or silicon oxide.
As shown in
a plurality of fourth connection pad groups. Each fourth connection pad group is used to be connected an electronic element, and includes a cathode bonding pad and an anode bonding pad arranged in pair. A body material layer included in a fourth connection pad soldered to the cathode pin of the electronic element is referred to as a cathode bonding pad, and a body material layer included in a fourth connection pad soldered to the anode pin of the electronic element is referred to as an anode bonding pad. As shown in
In a specific implementation, in the functional backplane provided in the embodiments of the present disclosure, as shown in
In some embodiments, as shown in
As shown in
Specific connections between the plurality of fourth connection pad groups are not limited.
It can be understood that the drive method of the functional backplane is not limited. As shown in
When the micro integrated circuit chip provides the signal to the light-emitting unit, each micro integrated circuit chip includes a plurality of pins, and the wiring board further includes fifth connection pads located in the active area and bonded to pins of the micro integrated circuit chips. The fifth connection pad has a similar structure as the fourth connection pad, and may be manufactured by using the same film layer structure as the fourth connection pad. A plurality of electronic elements may be divided into a plurality of lamp areas, and each lamp area includes at least one electronic element. Each micro integrated circuit chip is used for driving electronic elements in at least one lamp area to emit light.
Some embodiments of the present disclosure provide a manufacturing method of a wiring board. The manufacturing method includes following steps.
A mother board 1 and a daughter board 2 are manufactured separately. The mother board 1 includes a first substrate 11 and a first wiring layer 12 formed on the first substrate 11. The first wiring layer 12 includes at least one first connection pad 122. The daughter board 2 includes a second substrate 21 and a second wiring layer 22 formed on the second substrate 21. The second wiring layer 22 includes at least one second connection pad 221.
The first wiring layer 12 may further include driving element(s) 121 in addition to the at least one first connection pad 122. For example, in an example where the mother board 1 has an active area A and a passive area B located on a side of the active area A, the driving element(s) 121 may be located in the active area A, the at least one first connection pad 122 may be located in the passive area B, and the at least one first connection pad 122 is electrically connected to the driving element(s) 121. During manufacturing, the driving element(s) 121 and the at least one first connection pad 122 may be formed by one patterning process.
For example, in some embodiments, manufacturing the mother board 1, includes following steps.
The first wiring layer 12 is formed on the first substrate 11.
The first substrate 11 may be a rigid substrate or a flexible substrate. For example, in a case where the first substrate 11 is the rigid substrate, the first substrate 11 may be a glass substrate or a ceramic substrate, and in this case, the first wiring layer 12 may be directly formed on the first substrate 11. In a case where the first substrate 11 is the flexible substrate, the first substrate 11 may be supported by a rigid substrate to form the first wiring layer 12 on the first substrate 11, and the first substrate 11 on which the first wiring layer 12 is formed is peeled from the rigid substrate finally.
In some examples, manufacturing the mother board, specifically includes following steps.
In Step 1), a first sub-metal layer 12a_1, a first sub-routing layer 12a_2, and a second sub-metal layer 12a_3 are formed on a base substrate 1. A material of the first sub-metal layer 12a_1 and a material of the second sub-metal layer 12a_3 each may be a molybdenum-containing alloy. The molybdenum-containing alloy has adhesion and oxidation resistance, may be manufactured by a sputtering process, and has a thickness in a range of hundreds to thousands of angstroms (Å). A material of the first sub-routing layer 12a_2 may be copper. The first sub-routing layer 12a_2 may have a thickness in a range of 1 μm to 5 μm, inclusive, and may be formed by a sputtering process or an electroplating process.
Of course, the first sub-metal layer 12a_1, the first sub-routing layer 12a_2 and the second sub-metal layer 12a_3 each may be formed by continuous deposition and patterning processes.
In Step 2), a first passivation layer (made of SiN) 131 is deposited, and is patterned to form vias. The first passivation layer 131 has a thickness in a range of 1000 Å to 4000 Å, inclusive.
In Step 3), a first planarization layer 141 is formed on the first substrate 11 on which the first passivation layer 131 is formed, and is patterned to form vias.
In Step 4), an adhesion layer 15 and a second routing layer are formed. The second routing layer 12b includes first connection pad(s) 122 and fourth connection pads 123. The adhesion layer 15 is electrically connected to the second sub-metal layer 12a_3 through the vias in the first passivation layer 131 and the vias in the first planarization layer 141.
In Step 5), a second passivation layer 132, a second planarization layer 142 and a protective layer 16 are deposited, and are patterned to expose the first connection pad(s) 122.
An orthographic projection of the first connection pad 122 on the first substrate 11 may have a rectangular shape. As shown in
In some embodiments, similar to the first substrate 11, the second substrate 21 may also be a rigid substrate or a flexible substrate, which is not specifically limited here.
In some embodiments, in a case where the second substrate 21 is the rigid substrate, manufacturing the daughter board 2, includes a following step.
The second wiring layer 22 is directly formed on the second substrate 21 to obtain the daughter board 2.
The second substrate 21 may be, for example, a glass substrate, and in this case, the second wiring layer 22 may be formed on the second substrate 21 by film formation, exposure and development processes.
In some other embodiments, in a case where the second substrate 21 is the flexible substrate, manufacturing the daughter board 2, as shown in
In S11, a sacrificial layer 30 is formed on a third substrate 400.
For example, the sacrificial layer 30 may be modified, for example, decomposed or gasified, after being heated or irradiated with light, and may have a thickness in a range of 3 nm to 30 nm, inclusive.
The third substrate 400 may be used as a support layer. For example, a material
of the third substrate 400 may be selected from rigid materials such as glass, quartz and plastic.
In S12, the at least one second connection pad 221 is formed on the third substrate 400 on which the sacrificial layer 30 is formed.
Of course, in a case where the daughter board further includes at least one fan-out wiring 222 and at least one third connection pad 223, the at least one third connection pad 223 and the at least one second connection pad 221 may be formed by one patterning process.
The second connection pad 221 may have a stacked structure of Ti/Al/Ti, Mo/Cu/Mo or Ti/Cu/Ti, and may be formed by film formation, exposure, development and etching processes.
In S13, a flexible film is formed on the third substrate 400 on which the at least one second connection pad 221 is formed, and at least one second via K2 is formed in the flexible film. Each second via K2 corresponds to a second connection pad 221.
The flexible film may be formed on the third substrate 400 by a coating process, and the at least one second via K2 may be formed in the flexible film by exposure, development and etching processes, so as to obtain the second substrate 21.
In order to facilitate peeling the second substrate 21 and the at least one second connection pad 221 from the third substrate 400 in a subsequent process, an edge of each second via K2 proximate to a corresponding second connection pad 221 is located within an orthographic projection of the second connection pad 221 on the second substrate 21, and a distance between an orthographic projection of the edge of each second via K2 on the second substrate 21 and an orthographic projection, on the second substrate 21, of edges of the second connection pad 221 corresponding to this second via K2 is in a range of 10 microns and 30 microns, inclusive, so that a contact area of the at least one second connection pad 221 and the second substrate 21 may be increased, thereby improving the peeling efficiency and preventing the at least one second connection pad 221 from falling off.
In the case where the daughter board further includes the at least one fan-out wiring 222 and the at least one third connection pad 223, manufacturing the daughter board 2, further includes: forming at least one fourth via K4 in the flexible film. Each fourth via K4 corresponds to a third connection pad 223.
In S14, a buffer layer 24 is formed on the third substrate 400 on which the at least one second via K2 is formed. The buffer layer 24 is provided with seventh via(s) K7 each corresponding to a second via K2, and eighth via(s) K8 each corresponding to a fourth via K4. The buffer layer 24 may function to isolate water and oxygen. The buffer layer 24 may be made of SiO, SiN or SiON, and may be formed by using film formation, exposure, development and etching processes.
In S15, a third wiring layer 40 is formed on the third substrate 400 on which the buffer layer 24 is formed. Each second connection pad 221 is electrically connected to the third wiring layer 40 through a second via K2.
In the case where the daughter board further includes the at least one fan-out wiring 222 and the at least one third connection pad 223, the third wiring layer 40 may include the at least one fan-out wiring 222. An end of a fan-out wiring 222 is electrically connected to the second connection pad 221 through a second via K2 and a seventh via, and another end of the fan-out wiring 222 is electrically connected to a third connection pad 223 through a fourth via K4 and an eighth via.
The third wiring layer 40 may have a stacked structure of Ti/Al/Ti, Mo/Cu/Mo or Ti/Cu/Ti, and may be formed by film formation, exposure, development and etching processes.
In S16, as shown in
In S17, an organic insulating layer 232 is formed on the third substrate 400 on which the inorganic insulating layer 231 is formed. The organic insulating layer 232 may be made of a resin material (e.g., an epoxy resin material), and may be formed by a coating process to have a planarization function.
In S19, the sacrificial layer 30 is heated, or is irradiated with light to separate the second substrate 21 and the at least one second connection pad 221 from the third substrate 400, so as to obtain the daughter board 2.
The second substrate 21 and the at least one second connection pad 221 may be peeled from the third substrate 400 by laser peeling. After the peeling, the at least one second connection pad 221 is exposed.
The manufacturing method of the wiring board 10 further includes S20 to S22. In S20, a bonding layer 3 is formed between the mother board 1 and the daughter board 2 to connect the mother board 1 and the daughter board 2. The daughter board 2 is formed on a side of the first substrate 11 away from the first wiring layer 12.
The bonding layer 3 may be, for example, an adhesive layer, and a material of the bonding layer 3 includes an adhesive. Before the sacrificial layer 30 is heated or irradiated with light to separate the second substrate 21 and the at least one second connection pad 221 from the third substrate 400, manufacturing the daughter board 2 further includes: sequentially forming a glue layer 500 and a release layer 600 on the third substrate 400 on which the third wiring layer 40 is formed in S18. After the sacrificial layer 30 is heated or irradiated with light to separate the second substrate 21 and the at least one second connection pad 221 from the third substrate 400, the manufacturing method of the wiring board 10 further includes: removing the release layer 600 to expose the glue layer 500, so as to adhere the mother board 1 to the daughter board 2 by using the glue layer in S20.
In S21, as shown in
For example, the at least one side wiring 4 may be formed by using film formation, exposure, development and etching processes, or the at least one side wiring 4 may be formed by using an inkjet printing process, which is not specifically limited here.
In some embodiments, in a case where the active area A and the passive area B are arranged in sequence in a first direction (indicated by the arrow a in
In this case, the orthographic projection(s) of the at least one second connection pad 221 and the orthographic projection(s) of the at least one first connection pad 122 may be aligned in one-to-one correspondence in the first direction by providing alignment marks on the second substrate 21 and the first substrate 11.
In some embodiments, an alignment accuracy of the orthographic projection(s) of the at least one second connection pad 221 and the orthographic projection(s) of the at least one first connection pad 122 in the first direction is controlled in a range of ±15 microns.
In theory, when a center of the orthographic projection of the first connection pad 122 in the second direction and a center of the orthographic projection of the second connection pad 221 in the second direction are located on a same straight line extending along the first direction, the orthographic projection of the first connection pad 122 and the orthographic projection of the second connection pad 221 are considered to be completely aligned. However, if the center of the orthographic projection of the second connection pad 221 in the second direction is shifted to the left or the right in the second direction with respect to the center of the orthographic projection of the first connection pad 122 in the second direction, the alignment accuracy may be represented by a range consisting of a negative shift amount of the left shift and a positive shift amount of the right shift. That is, when the center of the orthographic projection of the second connection pad 221 in the second direction is shifted by 15 microns to the left with respect to the center of the orthographic projection of the first connection pad 122 in the second direction, the alignment accuracy is −15 microns, and when the center of the orthographic projection of the second connection pad 221 in the second direction is shifted by 15 microns to the right with respect to the center of the orthographic projection of the first connection pad 122 in the second direction, the alignment accuracy is ±15 microns.
In S22, a protective layer 6 is formed on the mother board 1 and the daughter board 2 on which the at least one side wiring 4 is formed. The protective layer 6 is formed on the at least one side wiring 4, and an orthographic projection of edges of the protective layer 6 on the first substrate 11 exceeds an orthographic projection of edges of the at least one side wiring 4 on the first substrate 11.
The protective layer 6 may be made of an inorganic insulating material (e.g., SiN) or an organic material (e.g., an epoxy resin material), and may be formed by a deposition process or a printing process.
In some embodiments, as shown in
In S23, electronic elements 20 (e.g., light-emitting diode(s), LED) are soldered to the mother board 1, and each electronic element 20 is electrically connected to a portion (e.g., a driving element) of the first wiring layer 12 on the mother board 1 located in the active area A.
In S24, an encapsulation layer 700 is formed on the mother board 1 on which the electronic elements 20 are formed. In a case where the electronic element 20 is a micro inorganic light-emitting diode, the encapsulation layer 700 includes a portion covering the electronic elements 20 and a portion filling gap regions between the electronic elements 20. The encapsulation layer 700 may be an organic resin or a silica gel material in black, dark green, or dark gray. Since the inorganic light-emitting diode has a large light-emitting brightness, and the portion of the encapsulation layer 700 covering surfaces of the electronic elements 20 has a thickness of less than that of the portion of the encapsulation layer 700 filling the gap regions between the electronic elements 20, the light-emitting effect of the micro inorganic light-emitting diode may not be affected, and a high contrast may be achieved. For example, the encapsulation layer 700 may be manufactured by a coating process, a printing process, a filming-sticking process, a semiconductor film formation process, or a patterning process.
In S25, the circuit board 300 is bonded to the daughter board 2.
The sequence of S23, S24 and S25 may be adjusted according to actual needs. For example, the circuit board 300 may be bonded to the daughter board 2 firstly, and then, the encapsulation layer 700 is formed on the mother board 1 on which the electronic elements 20 are formed.
The foregoing descriptions are merely specific implementations of the present disclosure. However, the protection scope of the present disclosure is not limited thereto. Changes or replacements that any person skilled in the art could conceive of within the technical scope of the present disclosure shall be included in the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure shall be subject to the protection scope of the claims.
This application is a national phase entry under 35 USC 371 of International Patent Application No. PCT/CN 2022/077130 filed on Feb. 21, 2022, which is incorporated herein by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/CN2022/077130 | 2/21/2022 | WO |