Abstract:
A method for providing electrical connections to both sides of a touch sensor panel is disclosed. The method comprises forming conductive traces on a first surface of a base film, shaping the base film to form first and second attachment areas that include the conductive traces, forming a conductive shield over the conductive traces, wherein the shield is electrically coupled to one or more of the conductive traces, and folding the base film such that the conductive traces on the first and second attachment areas are positioned and aligned for attachment to pads on first and second sides of the touch sensor panel.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. patent application Ser. No. 12/122,441, filed May 16, 2008, the entire disclosure of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     This relates generally to touch sensor panels, and more particularly, to cost-effective flex circuit designs capable of being attached to both sides of a touch sensor panel. 
     BACKGROUND OF THE INVENTION 
     Many types of input devices are presently available for performing operations in a computing system, such as buttons or keys, mice, trackballs, joysticks, touch sensor panels, touch screens and the like. Touch screens, in particular, are becoming increasingly popular because of their ease and versatility of operation as well as their declining price. Touch screens can include a touch sensor panel, which can be a clear panel with a touch-sensitive surface, and a display device such as a liquid crystal display (LCD) that can be positioned partially or fully behind the panel so that the touch-sensitive surface can cover at least a portion of the viewable area of the display device. Touch screens can allow a user to perform various functions by touching the touch sensor panel using a finger, stylus or other object at a location dictated by a user interface (UI) being displayed by the display device. In general, touch screens can recognize a touch event and the position of the touch event on the touch sensor panel, and the computing system can then interpret the touch event in accordance with the display appearing at the time of the touch event, and thereafter can perform one or more actions based on the touch event. 
     Mutual capacitance touch sensor panels can be formed from a matrix of drive and sense lines of a substantially transparent conductive material such as Indium Tim Oxide (ITO), sometimes arranged in rows and columns in horizontal and vertical directions on a substantially transparent substrate. In some touch sensor panel designs, ITO drive and sense lines can be formed on opposite sides of the same substrate in a configuration referred to herein as double-sided ITO (DITO). The substantially transparent drive and sense lines can be routed to one edge of the substrate for off-board connections using conductive (e.g. metal) traces in the border areas of the substrate where transparency is not required. However, it can be expensive to manufacture the one or more flex circuits that are required to provide off-board connectivity for the drive and sense lines. 
     SUMMARY OF THE INVENTION 
     This relates to a flex circuit having conductive traces formed on only one side of a base film for attaching to both sides of a DITO touch sensor panel. By having conductive traces formed on only one side of the base film, the number of process steps and fabrication cost can be reduced because only a single etching step is needed. Furthermore, because the flex circuit is thinner, the resultant space savings can be utilized for other features in a device without enlarging the overall device package. 
     The flex circuit can be formed from a base film and can be bonded to both the top and bottom sides of the touch sensor panel at one end of the touch sensor panel. The flex circuit can include conductive traces (e.g. copper) and an insulator formed only on the side of the flex circuit that faces the touch sensor panel when bonded to the touch sensor panel. The flex circuit can be formed with a bend so that it can be attached to pads formed on either side of the touch sensor panel. A tail, which can be integrally formed with the flex circuit, can extend away from the touch sensor panel and can contain tail conductors for attaching to a main logic board. 
     The flex circuit can include a first attachment area that can include active conductors and dummy conductors formed along its length for making electrical connections with pads on a top surface of the touch sensor panel. The flex circuit can also include a second attachment area that can include lower conductors formed at its distal ends for making electrical connections with pads on a bottom surface of the touch sensor panel. In some embodiments, lower conductors on the second attachment area are arranged in conjunction with active and dummy conductors on the first attachment area so that when the flex circuit is folded and bonded to the touch sensor panel, the lower conductors on the bottom surface of the touch sensor panel and the active and dummy conductors on the top surface are not on directly opposing sides of the touch sensor panel. This arrangement can minimize unwanted coupling of signals between the conductors. 
     All traces and conductors on the flex circuit can be formed on the same side of the flex circuit. Because the traces and conductors are formed on the same side of the flex circuit, no vias and plating are required, and a thinner flex circuit can be manufactured. As a result, a bend can be formed in the flex circuit with the very small radius required by the thinness of the touch sensor panel. The thinness of the flex circuit can have other advantages such as providing more room in the z-direction for other electronics and/or mechanical structures, or allowing for thinner overall devices. In addition, forming only a single layer of conductors and traces can reduce the number of process steps required (because only a single etching step is needed), which can reduce manufacturing costs. 
     In the first attachment area, a particular number of dummy conductors can be formed between the active conductors. The number of dummy conductors, and the spacing between the dummy conductors and the active conductors, can be chosen (e.g., empirically) in accordance with the type and thickness of the flex circuit and the cross-sectional dimensions of the conductors. By the proper selection of conductor spacing, enough space can remain between the conductors (dummy and active) to retain most of the ACF underneath the first attachment area, minimizing the amount of ACF that is squeezed out. 
     The second attachment area can include a base film (e.g. polyamide), upon which a conductive trace layer (e.g. plated copper) and an insulator (a.k.a. coverlay or cover film) can be formed. A stiffener, which also acts as a spacer, can be attached at the distal end of the second attachment area to ensure that sufficient bonding pressure is achieved at the distal end. 
     To provide enhanced shielding for the single-sided flex circuits, thin conductive films can be attached to both sides of the flex circuits. The flex circuit can include a base film upon which a layer of conductive traces (e.g. copper) and an insulator can be formed. One or more conductive traces can be held at a fixed potential (e.g. ground). In one embodiment, a first opening (or notch) in the insulator can be formed over a particular conductive trace that is held at a fixed potential such as ground. Conductive film can then be applied over the insulator, where it can conform to the shape of the opening and make electrical contact with one or more of the fixed potential traces to hold the conductive film at the fixed potential. When the conductive film is held at the fixed potential, it can serve as a shield for the conductive traces. 
     In another embodiment, before any conductive film is applied, a second opening (or notch) can also be formed through the base film and the insulator, while avoiding any conductive traces. Conductive film can then be applied over the insulator, where it can conform to the shape of the opening (or notch) and make electrical contact with one or more of the fixed potential traces to hold the conductive film at the fixed potential. Conductive film can then be applied over the base film, where it can conform to the hole and make electrical contact with the conductive film on the opposite side. In this manner, the conductive film on both sides of the flex circuit can be held at a fixed potential and serve as shields. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1   a  illustrates a side view of an exemplary flex circuit  100  according to embodiments of the invention. 
         FIG. 1   b  illustrates a perspective view of the exemplary flex circuit of  FIG. 1   a  according to embodiments of the invention. 
         FIG. 1   c  illustrates a side view of conductive traces formed on one side of a flex circuit base film according to embodiments of the invention. 
         FIG. 2   a  illustrates a top view of an exemplary first attachment area on the flex circuit of  FIG. 1   b  according to embodiments of the invention. 
         FIG. 2   b  illustrates a side view of an exemplary first attachment area on a flex circuit having a first conductor configuration. 
         FIG. 2   c  illustrates a side view of an exemplary first attachment area on a flex circuit having a second conductor configuration. 
         FIG. 2   d  illustrates a side view of an exemplary first attachment area on a flex circuit having a third conductor configuration according to embodiments of the invention. 
         FIG. 3  illustrates a top and side view of a distal end of an exemplary second attachment area as shown in  FIG. 1   b  according to embodiments of the invention. 
         FIG. 4   a  illustrates a side view of an exemplary flex circuit including conductive film on the top side and optionally the bottom side according to embodiments of the invention. 
         FIG. 4   b  illustrates a top view of an exemplary flex circuit with a hole in an insulator for holding at least one conductive film at a fixed potential according to embodiments of the invention. 
         FIG. 4   c  illustrates a top view of an exemplary flex circuit with a notch in an insulator for holding at least one conductive film at a fixed potential according to embodiments of the invention. 
         FIG. 4   d  illustrates a top view of an exemplary flex circuit with a different notch in an insulator for holding at least one conductive film at a fixed potential according to embodiments of the invention. 
         FIG. 4   e  illustrates a top view of an exemplary flex circuit with no notch, but with conductive films extending a beyond base film and connected together for holding both conductive films at a fixed potential according to embodiments of the invention. 
         FIGS. 5   a  and  5   b  illustrate perspective views of an exemplary flex circuit in its original flattened fabrication configuration according to embodiments of the invention. 
         FIG. 6  illustrates an exemplary computing system including a touch sensor panel connected to a panel subsystem using the flex circuit according to embodiments of the invention 
         FIG. 7   a  illustrates an exemplary mobile telephone having a touch sensor panel connected to a panel subsystem using the flex circuit according to embodiments of the invention. 
         FIG. 7   b  illustrates an exemplary digital media player having a touch sensor panel connected to a panel subsystem using the flex circuit according to embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In the following description of preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which it is shown by way of illustration specific embodiments in which the invention can be practiced. It is to be understood that other embodiments can be used and structural changes can be made without departing from the scope of the embodiments of this invention. 
     This relates to a flex circuit having conductive traces formed on only one side of a base film for attaching to both sides of a DITO touch sensor panel. By having conductive traces formed on only one side of the base film, the number of process steps and fabrication cost can be reduced because only a single etching step is needed. Furthermore, because the flex circuit is thinner, the resultant space savings can be utilized for other features in a device without enlarging the overall device package. 
     Although embodiments of the invention may be described and illustrated herein in terms of DITO touch sensor panels, it should be understood that embodiments of the invention are also applicable to other touch sensor panel configurations, such as configurations in which the drive and sense lines are formed on different substrates or on the back of a cover glass, and configurations in which the drive and sense lines are formed on the same side of a single substrate. 
       FIG. 1   a  illustrates a side view of an exemplary flex circuit  100  according to embodiments of the invention. Note that  FIG. 1   a  is not to scale, and has exaggerated dimensions, particularly in the z-direction, for purposes of illustration only. In the example of  FIG. 1   a , flex circuit  100  can be formed from base film  110  and can be bonded to both the top and bottom sides at one end of touch sensor panel  102 . Flex circuit  100  can include conductive traces  112  (e.g. copper) and insulator  114  formed only on the side of the flex circuit that faces touch sensor panel  102  when bonded to the touch sensor panel. In the exemplary embodiment of  FIG. 1   a , flex circuit  100  can be formed with bend  106  so that it can be attached to pads  116  and  142  formed on either side of touch sensor panel  102 . Tail  104 , which can be integrally formed with flex circuit  100 , can extend away from touch sensor panel  102  and can contain tail conductors  118  for attaching to a main logic board. 
       FIG. 1   b  illustrates a perspective view of the exemplary flex circuit of  FIG. 1   a  according to embodiments of the invention. Note that  FIG. 1   b  is also not to scale, and has exaggerated dimensions, particularly in the z-direction, for purposes of illustration only. In the example of  FIG. 1   b , flex circuit  100  can include first attachment area  104  that can include active conductors  120  and dummy conductors  122  formed along its length for making electrical connections with pads on a top surface of touch sensor panel  102 . Flex circuit  100  also includes second attachment area  106  that can include lower conductors  124  formed at its distal ends for making electrical connections with pads on a bottom surface of touch sensor panel  102 . In some embodiments, lower conductors  124  on second attachment area  106  are arranged in conjunction with active and dummy conductors  120  and  122  on first attachment area  104  so that when flex circuit  100  is folded and bonded to touch sensor panel  102 , the lower conductors on the bottom surface of the touch sensor panel and the active and dummy conductors on the top surface are not on directly opposing sides of the touch sensor panel. This arrangement can minimize unwanted coupling of signals between the conductors. 
     All traces  112  and conductors  118 ,  120 ,  122  and  124  on flex circuit  100  can be formed on the same side of the flex circuit according to embodiments of the invention. Although  FIGS. 1   a  and  1   b  illustrate bend  106  having an exaggerated radius for purposes of illustration only, in practice the bend can be required to have a very small radius given the thinness of touch sensor panel  100 . Because the traces and conductors are formed on the same side of flex circuit  100 , no vias and plating are required, and a thinner flex circuit can be manufactured. As a result, bend  106  can be formed with the very small radius required by the thinness of touch sensor panel  100 . In contrast, conventional flex circuits having traces on both sides require vias through the base film and plating to establish an electrical connection through the via. Because of the dual traces and plating, conventional flex circuits are generally stiffer and cannot form bends with very small radii. 
     The thinness of the flex circuit achieved according to embodiments of the invention can have other advantages such as providing more room in the z-direction for other electronics and/or mechanical structures, or allowing for thinner overall devices. In addition, forming only a single layer of conductors and traces can reduce the number of process steps required (because only a single etching step is needed), which can reduce manufacturing costs. 
       FIG. 1   c  illustrates a side view of conductive traces  112  formed on one side of base film  110  according to embodiments of the invention. As mentioned above, in conventional flex circuits with traces on both sides of a base film, vias are needed to make connections between layers, and therefore plating is needed to provide conductivity through the vias. However, when plating is applied over traces  112 , the traces become thicker, necessitating wider spacing between traces to ensure that shorts between traces do not occur. Because single-sided embodiments of the invention do not require plating, a finer pitch (P) between traces can be achieved, which can result in smaller flex circuits. 
       FIG. 2   a  illustrates a top view of an exemplary first attachment area on the flex circuit of  FIG. 1   b  according to embodiments of the invention. In the example of  FIG. 2   a , first attachment area  204  can be bonded down to touch sensor panel  202  with anisotropic conductive film (ACF), which can form a conductive bond between the conductors on the first attachment area and the pads on the touch sensor panel. Because pressure is used to bond first attachment area  204  to touch sensor panel  202 , some ACF can be squeezed out during bonding, as shown at  226 . In touch screen embodiments, where optical clarity of touch sensor panel  202  is important, it is desirable to minimize the amount of ACF that gets squeezed out during bonding so that it does not intrude into the substantially transparent areas of the touch sensor panel. 
       FIG. 2   b  illustrates a side view of exemplary first attachment area  204  on flex circuit  200  having a first conductor configuration. In the example of  FIG. 2   b , if active conductors  220  are spaced too closely together, there can be insufficient spaces between conductors to contain ACF  226 , and as a result, an excessive amount of the ACF can be squeezed out into the substantially transparent areas of the touch sensor panel. 
       FIG. 2   c  illustrates a side view of exemplary first attachment area  204  on flex circuit  200  having a second conductor configuration. In the example of  FIG. 2   c , if active conductors  220  are spaced too far apart, first attachment area  204  (which can be formed from flexible base film) can be pressed down and fill in much of the spaces between the conductors, and again there can be insufficient spaces between conductors to contain ACF  226 . As a result, an excessive amount of the ACF can once again be squeezed out into the substantially transparent areas of the touch sensor panel. 
       FIG. 2   d  illustrates a side view of exemplary first attachment area  204  on flex circuit  200  having a third conductor configuration according to embodiments of the invention. In the example of  FIG. 2   d , a particular number of dummy conductors  222  can be formed between active conductors  220 . The number of dummy conductors  222 , and the spacing between the dummy conductors and active conductors  220 , can be chosen (e.g., empirically) in accordance with the type and thickness of flex circuit  200  and the cross-sectional dimensions of the conductors. By the proper selection of conductor spacing, enough space can remain between the conductors (dummy and active) to retain most of the ACF underneath first attachment area  204 , minimizing the amount of ACF that is squeezed out. 
       FIG. 3  illustrates a top and side view of a distal end of an exemplary second attachment area as shown in  FIG. 1   b  according to embodiments of the invention. In the example of  FIG. 3 , second attachment area  306  can include base film  310  (e.g. polyamide), upon which conductive trace layer  312  (e.g. plated copper) and insulator  314  (a.k.a. coverlay or cover film) can be formed. Stiffener  328 , which also acts as a spacer, can be attached at the distal end of second attachment area  306  to ensure that sufficient bonding pressure is achieved at the distal end. 
     As mentioned above, conventional flex circuits having traces on both sides require vias formed in the base film and plating to establish an electrical connection through the via. Insulators are also required on both sides of the flex circuit to protect the conductive traces formed thereon. Because of the dual plated traces and dual insulators, and the overall increased thickness of conventional flex circuits, conventional dual-sided flex circuits provide shielding for the conductive traces. To provide enhanced shielding for single-sided flex circuits according to embodiments of the invention, thin conductive films can be attached to both sides of the flex circuits. 
       FIG. 4   a  illustrates a side view of an exemplary flex circuit  400  including conductive film  430  on the top side and optionally the bottom side  436  according to embodiments of the invention. Note that  FIG. 4   a  is not to scale, and has exaggerated dimensions for purposes of illustration only. In the example of  FIG. 4   a , flex circuit  400  can include base film  410 , upon which a layer of conductive traces  412  (e.g. copper) and an insulator  414  can be formed. One or more of conductive traces  412  can be held at a fixed potential (e.g. ground). In one embodiment, first opening (or notch)  432  in insulator  414  can be formed over a particular conductive trace that is held at a fixed potential such as ground. Conductive film  430  can then be applied over insulator  414 , where it can conform to the shape of opening  432  and make electrical contact with one or more of the fixed potential traces to hold the conductive film at the fixed potential. When conductive film  430  is held at the fixed potential, it can serve as a shield for conductive traces  412 . 
     In another embodiment, before any conductive film is applied, second opening (or notch)  434  can also be formed through base film  410  and insulator  414 , while avoiding any conductive trace  412 . Conductive film  430  can then be applied over insulator  414 , where it can conform to the shape of opening (or notch)  434  and make electrical contact with one or more of the fixed potential traces to hold the conductive film at the fixed potential. Conductive film  436  can then be applied over base film  410 , where it can conform to hole  434  and make electrical contact with conductive film  414  on the opposite side. In this manner, the conductive film on both sides of the flex circuit can be held at a fixed potential and serve as shields. 
       FIG. 4   b  illustrates a top view of exemplary flex circuit  400  with opening  432  or  434  in at least insulator  414  for holding at least one conductive film at a fixed potential according to embodiments of the invention. 
       FIG. 4   c  illustrates a top view of exemplary flex circuit  400  with notch  432  or  434  in at least insulator  414  for holding at least one conductive film at a fixed potential according to embodiments of the invention. 
       FIG. 4   d  illustrates a top view of exemplary flex circuit  400  with a different notch  432  or  434  in at least insulator  414  for holding at least one conductive film at a fixed potential according to embodiments of the invention. 
       FIG. 4   e  illustrates a top view of exemplary flex circuit  400  with no notch. In the embodiment of  FIG. 4   e , conductive films  430  and  436  extend beyond (overhang) base film  414  and are conductively bonded in the overhanging area for holding both conductive films at a fixed potential according to embodiments of the invention. 
       FIGS. 5   a  and  5   b  illustrate perspective views of exemplary flex circuit  500  in its original flattened fabrication configuration according to embodiments of the invention. In the example of  FIGS. 5   a  and  5   b , flex circuit  500  includes first attachment area  504  that include active conductors  520  and dummy conductors  522  formed along its length. Flex circuit  500  also includes second attachment area  506  that can include conductors  524  formed at its distal ends. In the example of  FIGS. 5   a  and  5   b , flex circuit  500  is formed from base film  510 , and includes conductive traces and an insulator (not shown) formed only on the side of the base film visible in  FIG. 5   b . Tail  504 , which is integrally formed as part of flex circuit  500 , contain tail conductors for connecting to connector  538 . 
       FIG. 6  illustrates exemplary computing system  600  that can include one or more of the embodiments of the invention described above. Computing system  600  can include one or more panel processors  602  and peripherals  604 , and panel subsystem  606 . Peripherals  604  can include, but are not limited to, random access memory (RAM) or other types of memory or storage, watchdog timers and the like. Panel subsystem  606  can include, but is not limited to, one or more sense channels  608 , channel scan logic  610  and driver logic  614 . Channel scan logic  610  can access RAM  612 , autonomously read data from the sense channels and provide control for the sense channels. In addition, channel scan logic  610  can control driver logic  614  to generate stimulation signals  616  at various frequencies and phases that can be selectively applied to drive lines of touch sensor panel  624 . In some embodiments, panel subsystem  606 , panel processor  602  and peripherals  604  can be integrated into a single application specific integrated circuit (ASIC). 
     Touch sensor panel  624  can include a capacitive sensing medium having a plurality of drive lines and a plurality of sense lines, although other sensing media can also be used. Each intersection of drive and sense lines can represent a capacitive sensing node and can be viewed as picture element (pixel)  626 , which can be particularly useful when touch sensor panel  624  is viewed as capturing an “image” of touch. (In other words, after panel subsystem  606  has determined whether a touch event has been detected at each touch sensor in the touch sensor panel, the pattern of touch sensors in the multi-touch panel at which a touch event occurred can be viewed as an “image” of touch (e.g. a pattern of fingers touching the panel).) Each sense line of touch sensor panel  624  can drive sense channel  608  (also referred to herein as an event detection and demodulation circuit) in panel subsystem  606 . Touch sensor panel  624  can be connected to panel subsystem  606 , panel processor  602  and peripherals  604  through the flex circuit according to embodiments of the invention. 
     Computing system  600  can also include host processor  628  for receiving outputs from panel processor  602  and performing actions based on the outputs that can include, but are not limited to, moving an object such as a cursor or pointer, scrolling or panning, adjusting control settings, opening a file or document, viewing a menu, making a selection, executing instructions, operating a peripheral device connected to the host device, answering a telephone call, placing a telephone call, terminating a telephone call, changing the volume or audio settings, storing information related to telephone communications such as addresses, frequently dialed numbers, received calls, missed calls, logging onto a computer or a computer network, permitting authorized individuals access to restricted areas of the computer or computer network, loading a user profile associated with a user&#39;s preferred arrangement of the computer desktop, permitting access to web content, launching a particular program, encrypting or decoding a message, and/or the like. Host processor  628  can also perform additional functions that may not be related to panel processing, and can be connected to program storage  632  and display device  630  such as an LCD display for providing a UI to a user of the device. Display device  630  together with touch sensor panel  624 , when located partially or entirely under the touch sensor panel, can form touch screen  618 . 
     Note that one or more of the functions described above can be performed by firmware stored in memory (e.g. one of the peripherals  604  in  FIG. 6 ) and executed by panel processor  602 , or stored in program storage  632  and executed by host processor  628 . The firmware can also be stored and/or transported within any computer-readable medium for use by or in connection with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch the instructions from the instruction execution system, apparatus, or device and execute the instructions. In the context of this document, a “computer-readable medium” can be any medium that can contain or store the program for use by or in connection with the instruction execution system, apparatus, or device. The computer readable medium can include, but is not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus or device, a portable computer diskette (magnetic), a random access memory (RAM) (magnetic), a read-only memory (ROM) (magnetic), an erasable programmable read-only memory (EPROM) (magnetic), a portable optical disc such a CD, CD-R, CD-RW, DVD, DVD-R, or DVD-RW, or flash memory such as compact flash cards, secured digital cards, USB memory devices, memory sticks, and the like. 
     The firmware can also be propagated within any transport medium for use by or in connection with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch the instructions from the instruction execution system, apparatus, or device and execute the instructions. In the context of this document, a “transport medium” can be any medium that can communicate, propagate or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The transport readable medium can include, but is not limited to, an electronic, magnetic, optical, electromagnetic or infrared wired or wireless propagation medium. 
       FIG. 7   a  illustrates exemplary mobile telephone  736  that can include touch sensor panel  724  and display device  730 , the touch sensor panel connected to a panel subsystem using the flex circuit according to embodiments of the invention. 
       FIG. 7   b  illustrates exemplary digital media player  740  that can include touch sensor panel  724  and display device  730 , the touch sensor panel connected to a panel subsystem using the flex circuit according to embodiments of the invention. The mobile telephone and media player of  FIGS. 7   a  and  7   b  can maintain a smaller, lower cost physical product by utilizing the flex circuit according to embodiments of the invention. 
     Although embodiments of this invention have been fully described with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of embodiments of this invention as defined by the appended claims.