PATENT DOCUMENT

Publication Number: US-10199323-B2
Application Number: US-201715415496-A
Country: US
Kind Code: B2

Title: Flexible circuit substrate with temporary supports and equalized lateral expansion

Abstract:
An item may have a flexible support structure and may include a flexible component. The flexible component may have electrical components mounted on component mounting regions in a flexible circuit substrate. The component mounting regions may be interconnected by serpentine interconnect paths or other flexible interconnect paths. The flexible circuit substrate and component mounting regions may extend along a longitudinal axis of the flexible component or may form a two-dimensional array. Two-dimensional mesh-shaped flexible circuit substrates may be used in forming displays. The mesh-shaped flexible circuit substrates may be auxetic substrates that widen when stretched (e.g., structures with a negative Poisson&#39;s ratio that become thicker perpendicular to applied force when stretched) and that therefore reduce image distortion. Temporary tethers may help hold flexible circuit substrates together until intentionally broken following assembly of a flexible component into the flexible support structure.

Claims:
What is claimed is: 
     
       1. A flexible component, comprising:
 a flexible circuit substrate having a plurality of component mounting regions interconnected by flexible interconnect paths; 
 temporary tethers that are configured to temporarily couple the component mounting regions together and strengthen the flexible circuit substrate when the temporary tethers are in an unbroken state, wherein the temporary tethers are broken during assembly of the flexible component into an item, wherein the temporary tethers are configured to remain in a broken state within the item, and wherein the temporary tethers are interspersed between the flexible interconnect paths; 
 metal lines in the flexible circuit substrate; and 
 electrical components that are mounted to the component mounting regions and that are interconnected by the metal lines. 
 
     
     
       2. The flexible component defined in  claim 1  wherein each of the temporary tethers has a narrowed region that facilitates breaking of the temporary tethers. 
     
     
       3. The flexible component defined in  claim 2  wherein the electrical components each include at least one light-emitting diode. 
     
     
       4. The flexible component defined in  claim 3  wherein the flexible circuit substrate comprises a polyimide layer, wherein the flexible interconnect paths comprise serpentine portions of the polyimide layer that extend from the component mounting regions, and wherein the temporary tethers are formed from integral portions of the polyimide layer. 
     
     
       5. The flexible component defined in  claim 1  wherein the flexible circuit substrate is an elongated flexible circuit substrate having a longitudinal axis, wherein the component mounting regions extend along the longitudinal axis, wherein the component mounting regions include adjacent pairs of component mounting regions, wherein each pair of adjacent component mounting regions is coupled by a respective set of the temporary tethers, and wherein each set of temporary tethers includes at least first and second tethers of different strengths. 
     
     
       6. An item, comprising:
 a flexible support structure; 
 an auxetic mesh-shaped flexible circuit substrate having a two-dimensional array of component mounting regions coupled by interconnect paths, wherein the flexible circuit substrate comprises a polymer, wherein portions of the flexible circuit substrate form temporary tethers, wherein the temporary tethers are configured to temporarily couple the component mounting regions together and strengthen the flexible circuit substrate when the temporary tethers are in an unbroken state, wherein the temporary tethers are broken during assembly of the item, and wherein the temporary tethers are configured to remain in a broken state within the item; and 
 an array of electrical components, wherein each electrical component is mounted to a respective one of the component mounting regions and is interconnected to at least one other of the electrical components with metal traces in the auxetic mesh-shaped flexible circuit substrate and wherein each electrical component comprises at least one light-emitting diode. 
 
     
     
       7. The item defined in  claim 6  wherein the auxetic mesh-shaped flexible circuit substrate comprises polyimide and wherein each electrical component includes at least one crystalline semiconductor die. 
     
     
       8. The item defined in  claim 7  wherein each crystalline semiconductor die comprises the at least one light-emitting diode. 
     
     
       9. The item defined in  claim 6  wherein the flexible support structure comprises fabric. 
     
     
       10. The item defined in  claim 6  wherein each temporary tether has a portion coupled to one of the interconnect paths. 
     
     
       11. The item defined in  claim 6  wherein each electrical component comprises a communications circuit and at least three light-emitting diodes. 
     
     
       12. The item defined in  claim 11  wherein each of the light-emitting diodes has a different color and is formed from a respective crystalline semiconductor die. 
     
     
       13. The item defined in  claim 12  wherein the support structure comprises strands of material and is configured to stretch. 
     
     
       14. The item defined in  claim 6  wherein the electrical components include sensors. 
     
     
       15. The item defined in  claim 6  further comprising a non-auxetic flexible circuit substrate structure coupled to the auxetic flexible circuit substrate.

Description:
This application claims the benefit of provisional patent application No. 62/381,382, filed Aug. 30, 2016, which is hereby incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     This relates generally to components formed from flexible circuit substrates, and, more particularly, to items formed from components with flexible circuit substrates having regions interconnected by elongated interconnect paths. 
     Electrical components such as integrated circuits can be mounted on dielectric substrates. Signals may be routed between electrical components using metal traces on a dielectric substrate. Some substrates such as rigid printed circuit boards are inflexible. Other substrates such as flexible printed circuit substrates may bend, thereby allowing these substrates to be used in applications were the inflexible nature of rigid printed circuit boards would not be acceptable. 
     It can be challenging to form flexible circuit substrates with desired attributes. If care is not taken, a flexible circuit substrate may be insufficiently flexible or may be insufficiently robust. Flexible circuit substrates may also distort undesirably when stressed. 
     SUMMARY 
     An item may have a flexible support structure. The flexible support structure may be formed from a stretchable material such as fabric, elastomeric polymer, or other stretchable structures. The item may include a flexible component that is supported by the flexible support structure. For example, the item may have a flexible component that is embedded within a fabric structure or that is attached to an elastomeric plastic support. The flexible component may have a flexible circuit substrate. The flexible component may also have electrical components mounted on component mounting regions in the flexible circuit substrate. The component mounting regions may be interconnected by serpentine interconnect paths or other flexible interconnect paths in the flexible circuit substrate. 
     The flexible circuit substrate may have an elongated shape that extends along a longitudinal flexible component axis or may have a two-dimensional shape. The electrical components mounted on the component mounting regions of the flexible circuit substrate may include touch sensors and other sensors, light-based components such as light-emitting diodes, communications and control circuit, and other circuitry. Two-dimensional mesh-shaped flexible circuit substrates may be used in forming displays. The mesh-shaped flexible circuit substrates may be auxetic substrates that widen when stretched (e.g., structures with a negative Poisson&#39;s ratio that become thicker perpendicular to applied force when stretched). A flexible component such as a flexible display that uses an auxetic substrate may exhibit reduced image distortion. 
     Temporary tethers may help hold flexible circuit substrates together until intentionally broken following assembly of a flexible component and flexible support structure to form an item. The temporary tethers may be formed from integral portions of a flexible circuit substrate or separate structures and may have selectively narrowed portions to facilitate splitting the tethers in known locations. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a diagram of an illustrative item of the type that may include circuitry mounted on a flexible circuit substrate in accordance with an embodiment. 
         FIG. 2  is a perspective view of circuitry on a flexible circuit substrate having component mounting regions interconnected by stretchable elongated serpentine interconnect paths in accordance with an embodiment. 
         FIG. 3  is a top view of a pair of component mounting regions, an interposed serpentine interconnect path, and temporary support structures in accordance with an embodiment. 
         FIGS. 4, 5, 6, 7, 8, 9, 10, and 11  are illustrative temporary support structures in accordance with embodiments. 
         FIG. 12  is a diagram of an illustrative pair of component mounting regions formed from flexible circuit substrate material that have been coupled by temporary support structures that are separate from the flexible circuit substrate material in accordance with an embodiment. 
         FIG. 13  is a diagram of an illustrative pair of component mounting regions formed from flexible circuit substrate material that have been coupled by temporary support structures that extend outwardly from the component mounting regions in accordance with an embodiment. 
         FIG. 14  is a perspective view of an illustrative stretchable item showing how the item may be formed from a flexible circuit substrate material that expands laterally in a direction that is perpendicular to a stretching direction in accordance with an embodiment. 
         FIG. 15  is a diagram of an illustrative auxetic mesh flexible circuit substrate in an unstretched configuration in accordance with an embodiment. 
         FIG. 16  is a diagram of the auxetic mesh flexible circuit substrate of  FIG. 15  when stretched in accordance with an embodiment. 
         FIGS. 17, 18, and 19  are diagrams of additional illustrative patterns that may be used for forming auxetic mesh flexible printed circuit substrates in accordance with embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     An illustrative item that may include a component formed from a flexible circuit substrate is shown in  FIG. 1 . As shown in  FIG. 1 , item  10  may be formed from support structure  12 . Support structure  12  may include one or more layers of fabric or other material that includes strands of material such as strands  14  (e.g., insulating and/or conductive yarn), may be formed from sheets of plastic, molded or machined plastic structures, metal structures, structures formed from fiber-composite material, and/or structures formed from other materials. Structure  12  may form a wearable item (e.g., a band to be worn on a user&#39;s wrist), may form an electronic device housing (e.g., a housing for a cellular telephone, laptop computer, tablet computer, or other electronic device), may form a case or cover for an electronic device, and/or may form other suitable items. If desired, item  10  may be flexible. For example, structure  12  may be flexed in directions  20  about bend axis  18 . Structures  12  may also be deformed in other directions (e.g., by stretching). 
     One or more components such as illustrative component  16  may be supported by support structure  12 . For example, component  16  may be embedded within structure  12  (e.g., component  16  may be received within a pocket between adjacent fabric layers, may be mounted in a recess in a plastic or metal structure, may be attached to an interior and/or exterior portion of structure  12  using adhesive, or may otherwise be incorporated into structure  12 ). To accommodate deformation of structure  12 , component  16  may be formed from a flexible circuit substrate. 
     An illustrative flexible electronic component formed from a flexible circuit substrate is shown in  FIG. 2 . As shown in the perspective view of  FIG. 2 , flexible electronic component  16  may be formed from flexible circuit substrate  22 . Flexible circuit substrate  22  may be formed from a flexible dielectric material such as polyimide or other flexible polymer that allows component  16  to flex. Component  16  may, for example, stretch longitudinally outward in directions  30  (e.g., along a longitudinal axis associated with an elongated component such as illustrative component  16  of  FIG. 2 ) and/or may bend about bend axis  18 . 
     Electrical components  24  may include packaged and/or unpackaged integrated circuits or other semiconductor dies. Unpackaged circuits may be formed from bare silicon dies or other crystalline semiconductor dies. Packaged integrated circuits may be encapsulated within plastic packages. If desired, packaged circuits and/or unpackaged circuits may be mounted on interposer structures. Integrated circuit packages, interposers, and other structures for packaging and mounting circuitry associated with electrical components  24  may be formed from plastic, ceramic, and/or other dielectric materials. 
     Electrical components  24  may include devices for gathering input and/or supplying output. With one illustrative configuration, components  24  may include light-emitting diodes such as light-emitting diodes  26  and associated control and communications circuitry such as circuitry  28 . Light-emitting diodes  26  may be formed from organic light-emitting diode structures or may be formed from crystalline semiconductor dies (e.g., light-emitting diodes  26  may be micro-LEDs). There may be any suitable number of light-emitting diodes  26  in each components  24  (e.g., one or more, two or more, three or more, etc.). The light-emitting diodes in each component  24  may be light-emitting diodes  26  of different colors such as red, green, and blue light-emitting diodes. In general, components  24  may be any suitable electrical components (e.g., integrated circuits, discrete components, light-emitting components, light sensors, touch sensor components such as capacitive touch sensor components, light-emitting and light-detecting touch sensor components, force sensors, temperature sensors, pressure sensors, moisture sensors, other sensors, haptic output devices, audio components, etc.). Illustrative configurations in which components  24  include at least some light-emitting components such as light-emitting diodes  26  and that optionally include touch sensor components may sometimes be described herein as an example. This is, however, merely illustrative. Components  24  may be any suitable electrical components mounted to flexible circuit substrate  22 . 
     Flexible circuit substrate  22  may have component mounting regions such as component mounting regions  22 CM that are interconnected by flexible interconnect paths (sometimes referred to as branches, arms, elongated segments, interconnects, etc.) such as flexible interconnect paths  22 I. Signal routing lines  32  may be formed from metal traces in component mounting regions  22 CM and interconnect paths  22 I. Interconnect paths  22 I may have serpentine shapes or other suitable elongated shapes (e.g., meandering elongated shapes, etc.) to promote stretching and bending without damaging signal routing lines  32 . Components  24  may be soldered to signal path solder pads formed from metal traces in component mounting regions  22 CM or may be coupled to signal lines  32  using other suitable conductive connections (e.g., conductive connections formed from welds, conductive adhesive, etc.). Component mounting regions  22 CM may be rectangular, circular, oval, may have shapes with combinations of curved and straight edges, or may have other suitable shapes. 
     Flexible circuit substrate  22  may be formed from a flexible polymer such as polyimide or other flexible dielectric. Substrate  22  may, for example, include one or more, two or more, or three or more sheets of laminated polyimide (as examples). Metal traces may be formed on one or both sides of substrate  22  and/or may be embedded between polyimide sublayers in substrate layer  22 . 
     Component mounting regions  22 CM may be arranged in a line (e.g., to form a one-dimensional array), may be tiled in two dimensions (e.g., to form a two-dimensional array having rows and columns), and/or may be organized in other suitable patterns. Light-emitting diodes  26  and other electrical devices associated with electrical components  24  may be used to create components  16  that serve as status indicator lights, displays that display images for a user, and/or other components  16 . Components  24  that include sensors (e.g., capacitive touch sensing circuitry, force sensors, light-based touch sensors, etc.) can be formed in one-dimensional arrays (e.g., to serve as buttons or one-dimensional touch sensitive input devices) or may be formed in two-dimensional arrays (e.g., to form two-dimensional touch sensors). If desired, a two-dimensional mesh-shaped configuration may be used for substrate  22 , components  24  may be mounted on a two-dimensional array of regions  22 CM, and component  16  may form a two-dimensional touch sensitive display (as an example). Haptic devices may be incorporated into electrical components  24  to provide component  16  with haptic output capabilities. 
     Whether arranged to form a one-dimensional or two-dimensional array or other suitable flexible circuit configuration, flexible circuit substrate  22  may be delicate due to the presence of thin elongated structures such as interconnect paths  22 I. To ensure that flexible circuit substrate  22  is sufficiently robust to withstand handling during assembly such as when being attached to support structure  12  of item  10  ( FIG. 1 ), flexible circuit substrate  22  may be provided with temporary support structures such as breakable tethers  34  of  FIG. 3 . Tethers  34  may be formed from the same material as substrate  22  (e.g., polyimide) or may be formed from a different material (e.g., an organic or inorganic material that is coupled between opposing portions of substrate  22 ). Substrate  22  may be patterned using laser cutting, die cutting, etching, photoimaging (e.g., using a mask to expose and develop a photoimageable to form polymer substrate  22 ), printing and/or other suitable patterning techniques. During patterning, tethers  34  may be left in place in substrate  22  at locations that bridge gaps  36  between component mounting regions  22 CM and interconnect paths  22 I or at other suitable locations that help provide temporary support to substrate  22  (e.g., temporary coupling between component mounting regions  22 M). Once component  16  has been mounted in structure  12 , component  16  may be flexed or otherwise manipulated to break tethers  34  and thereby release serpentine interconnect paths  22 I. This ensures that flexible circuit substrate  22  and component  16  will achieve its desired maximum flexibility during normal use of item  10 . 
     If desired, tethers  34  may have narrowed portions  34 ′ or other selectively weakened portions. Narrowed portions  34 ′ serve as stress concentrators that ensure that tethers  34  break in a controllable fashion at known locations during manufacturing. Tethers  34  may all have the same strength or different tethers within the set of tethers coupling together adjacent pairs of component mounting regions  22 CM may have different strengths. Tethers of different strengths can be broken by applying progressively increasing amounts of force. In the example of  FIG. 3 , the widths of narrowed portions  34 ′ increase progressively for tethers  34 - 1 ,  34 - 2 , and  34 - 3 . With this arrangement, tether  34 - 1  breaks relatively easily, tether  34 - 2  breaks with more difficulty than tether  34 - 2  and therefore breaks only after more force is applied than was applied to break tether  34 - 1 , and tether  34 - 3  breaks when even more force is applied than was used to break tether  34 - 2 . Different amounts of breaking force may be applied at different manufacturing stages so that component  16  has different amounts of flexibility at different stages. 
     In the illustrative configuration of  FIG. 3 , tethers  34  have a bowtie shape with a narrowed central portion  34 ′.  FIG. 4  shows how tether  34  may be narrowed from one side. Tether  34  of  FIG. 5  has an edge with curved portions.  FIG. 6  shows how tether  34  may have a sawtooth shape. In the example of  FIG. 7 , tether  34  has rectangular slot  38  that facilitates breakage. In the example of  FIG. 8 , tether  34  has an oval or teardrop shaped opening  40  that facilitates breakage. Tether  34  of  FIG. 9  is selectively weakened by the presence of comb-shaped narrowing edge recesses  42 .  FIG. 10  shows how tether  34  may be narrowed using rectangular notches. Tether  34  of  FIG. 11  has pointed notches. 
     As shown in  FIG. 12 , tethers  34  may be formed from material that is separate from the material of flexible circuit substrate  22 . Tethers  34  may, in general, be formed from plastic, metal, ceramic, printed material, material attached to substrate  22  by adhesive or other attachment mechanisms, or other suitable materials. If desired, tethers  34  may extend outwardly from component mounting regions  22 CM, as shown in  FIG. 13 . The configurations of  FIGS. 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, and 13  are merely illustrative. In general, tethers  34  may have any suitable shapes or sizes and may be formed from integral portions of substrate  22  and/or one or more additional materials. Tethers  34  serve as temporary attachment structures that help hold component mounting regions  22 CM together during assembly so that interconnect paths  22 I are not damaged and may therefore sometimes be referred to as being sacrificial, breakable, temporary, etc. 
       FIG. 14  shows how item  10  may be stretchable. In the example of  FIG. 14 , structure  12  of item  10  is being stretched around a cylindrical object  40  in directions  42 . Object  40  may be, for example, a wrist of a person, may be another human body part, may be an inanimate object, or may be any other suitable structure. In configurations such as those in which components  24  contain light-emitting diodes in a two-dimensional array to form a display that displays images for a user, distortion of displayed images may be undesirable. To prevent flexible circuit substrate  22  of item  10  from deforming in a way that distorts displayed images as item  10  is stretched along a first dimension (parallel to directions  42 ) flexible circuit substrate  22  (and, if desired, structure  12 ) may contain structures that expand outwardly in a perpendicular second dimension (parallel to directions  44 ) as flexible circuit substrate  22  is stretched in directions  42 . Because circuit substrate  22  stretches outwardly in directions  44  as structure  12  and circuit substrate  22  are stretched in directions  42 , substrate  22  and the components  24  on substrate  22  will expend outwardly by equal amounts. The pitch (center-to-center spacing) of components  24  may increase, but pitch expansion will occur equally in the dimension parallel to directions  42  and in the orthogonal dimension parallel to directions  44  so the array of components  24  on substrate  22  will not become distorted and will not produce distorted images. 
     Materials that exhibit equal expansion in orthogonal directions when stretched (e.g., structures that become thicker/wider perpendicular to applied force when stretched) are characterized by a negative Poisson&#39;s ratio and may sometimes be referred to as auxetics. Distortion of the array of components  24  in component  16  can therefore be minimized by forming component  16  from an auxetic flexible circuit substrate. In general, substrate  22  may be provided with any suitable patterns of component mounting regions and interconnect paths  22 I that form an auxetic flexible circuit substrate. For example, substrate  22  may be formed from an auxetic mesh-shaped patterned polyimide layer or other substrate shape in which paths  22 I help laterally press apart substrate  22  when stretched. 
       FIGS. 15 and 16  are top views of an illustrative flexible circuit substrate  22  that has an auxetic configuration. Initially, substrate  22  may have an unexpanded configuration of the type shown in  FIG. 15 . When substrate  22  of  FIG. 15  is stretched outwardly in directions  42 , each component mounting region  22 CM will rotate, as shown by arrows  46  of  FIG. 15 . This causes elongated interconnect paths  22 I to move into the configuration of  FIG. 16  so that component mounting regions  22 CM and components  24  on regions  22 CM are moved outwardly in direction  44  and so that substrate  22  expands equally in both directions  42  and directions  44 . Interconnect paths  22 I may be elongated straight segments (as shown in  FIG. 16 ) or may have elongated serpentine shapes as shown in  FIG. 2 . Substrates such as substrates  22  of  FIGS. 15 and 16  may sometimes be referred to as auxetic mesh substrates because interconnect paths  22 I form a two-dimensional lattice interconnecting a two-dimensional array of component mounting regions  22 CM and components  24 . 
     Additional illustrative mesh-shaped flexible circuit substrates  22  for component  16  are shown in  FIGS. 17, 18, and 19 . As shown in  FIGS. 17, 18, and 19 , substrate  22  may have various different auxetic mesh patterns that expand equally in directions  44  and  42  when stretched in direction  42 . The flexible circuit substrate may, if desired, include optional non-auxetic portions  22 NA (i.e., flexible substrate regions with positive Poisson&#39;s ratio) formed from serpentine interconnect paths  22 I′ or other suitable substrate material. As shown in  FIGS. 17, 18, and 19 , temporary tethers  34  may, if desired, be used in holding paths  22 I and/or  22 I′ of the flexible circuit substrates of  FIGS. 17, 18, and 19  together as components  16  are assembled with structures  12  to form item  10 . 
     The foregoing is merely illustrative and various modifications can be made to the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20170125
Publication Date: 20190205
Grant Date: 20190205
Priority Date: 20160830
Inventors: HSU, YUNG-YU
KIM, HOON SIK
SCHULTZ, CHRISTOPHER A.
KINDLON, DAVID M.
SUNSHINE, Daniel D.
DRZAIC, PAUL S.
ALOUSI, SINAN
SHYU, TERRY C.
Assignee: APPLE INC
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Family ID: 61243437