PATENT DOCUMENT

Publication Number: US-10957678-B2
Application Number: US-201916688638-A
Country: US
Kind Code: B2

Title: Display module and system applications

Abstract:
A display module and system applications including a display module are described. The display module may include a display substrate including a front surface, a back surface, and a display area on the front surface. A plurality of interconnects extend through the display substrate from the front surface to the back surface. An array of light emitting diodes (LEDs) are in the display area and electrically connected with the plurality of interconnects, and one or more driver circuits are on the back surface of the display substrate. Exemplary system applications include wearable, rollable, and foldable displays.

Claims:
What is claimed is: 
     
       1. An electronic device comprising:
 a substrate including a first side and a second side; 
 a first wiring layer on the first side; 
 
       an array of LEDs on and in electrical contact with the first wiring layer on the first side of the substrate; 
       a second wiring layer on the second side of the substrate;
 a plurality of interconnects extending between and electrically connecting the first wiring layer to the second wiring layer. 
 
     
     
       2. The electronic device of  claim 1 , further comprising an array of micro chips connected with the first wiring layer to drive the array of LEDs. 
     
     
       3. The electronic device of  claim 2 , wherein each micro chip is connected with a corresponding plurality of LEDs. 
     
     
       4. The electronic device of  claim 3 , wherein the array of LEDs is located in a display area of the substrate. 
     
     
       5. The electronic device of  claim 4 , further comprising a timing controller chip electrically connected with the second wiring layer. 
     
     
       6. The electronic device of  claim 5 , wherein the array of micro chips is interspersed among the array of LEDs. 
     
     
       7. The electronic device of  claim 4 , further comprising a plurality of integrated circuit (IC) chips in electrical connection with the second wiring layer. 
     
     
       8. The electronic device of  claim 7 , wherein the plurality of interconnects is located outside of the display area. 
     
     
       9. The electronic device of  claim 7 , wherein the plurality of interconnects is located directly behind the display area. 
     
     
       10. The electronic device of  claim 7 , further comprising a driver integrated circuit (IC) chip on the first side of the substrate and in electrical connection with the first wiring layer. 
     
     
       11. The electronic device of  claim 1 , wherein the substrate includes a display area and a bevel width around the display area, wherein the bevel width is less than 1 mm. 
     
     
       12. The electronic device of  claim 11 , wherein the substrate is flexible. 
     
     
       13. The electronic device of  claim 11 , wherein the substrate further comprises a contact ledge area, wherein the contact ledge area is wider than the bevel width. 
     
     
       14. The electronic device of  claim 13 , further comprising a driver IC bonded to the first wiring layer in the contact ledge area. 
     
     
       15. The electronic device of  claim 11 , wherein the bevel width completely surrounds the display area.

Description:
RELATED APPLICATIONS 
     This application is a continuation of co-pending U.S. patent application Ser. No. 16/145,879, filed Sep. 28, 2018, which is a continuation of U.S. patent application Ser. No. 15/908,505, filed Feb. 28, 2018, now U.S. Pat. No. 10,147,711, which is a continuation of U.S. patent application Ser. No. 15/417,015, filed Jan. 26, 2017, now U.S. Pat. No. 9,922,966, which is a continuation of U.S. patent application Ser. No. 15/157,235, filed May 17, 2016, now U.S. Pat. No. 9,582,036, which is a continuation of U.S. patent application Ser. No. 14/109,864, filed on Dec. 17, 2013, now U.S. Pat. No. 9,367,094 which is incorporated herein by reference. 
    
    
     BACKGROUND 
     Field 
     The present invention relates to display modules. More particularly embodiments of the present invention relate to display module packages and system applications thereof. 
     Background Information 
     Light emitting diodes (LEDs) are increasingly being considered as a replacement technology for existing light sources. For example, LEDs are found in signage, traffic signals, automotive tail lights, mobile electronic displays, and televisions. Some specific mobile electronics are smart electronic devices, such as smartphones, smartwatches, etc. including more advanced computing capability than a feature phone or watch. Demand is increasing for thinner, lighter weight, and lower cost smart electronic devices, with higher resolution and larger touch screens. Organic light emitting diode (OLED) display and liquid crystal display (LCD) are the two most widely adopted display technologies in current smart electronic devices. 
     OLED technology generally includes a layer of an organic compound in a pixel area, and a thin film transistor (TFT) backplane to switch each individual pixel on or off. An OLED display works without a backlight and can display deep black levels. The organic compound layer is sensitive to air and moisture, which can lead to degradation of the display. OLED displays are typically encapsulated with a rigid glass cover to protect the organic compound from air and moisture. 
     LCD technology generally includes pixels filled with liquid crystals, and a thin film transistor (TFT) backplane to switch each individual pixel on or off. Since the liquid crystals do not produce light by themselves, they need backlight illumination from behind or side of the display panel. 
     Two widely adopted manners for packaging display modules based on OLED or LCD include chip-on-glass (COG) packaging and chip-on-film (COF) packaging.  FIGS. 1A-1B  are exemplary schematic cross-sectional side view and schematic front view illustrations of a COG packaged display module. As illustrated, the display module  100  includes a display panel  115  connected to a printed circuit board (PCB)  106  by a flexible printed circuit (FPC)  108 . The display panel  115  includes a display substrate  102  formed of either OLED or LCD display technologies, one or more driver ICs  110  mounted on the display substrate  102  and a cover  114  over the display substrate. A seal ring  113  may surround the display area  101  of the display substrate for attaching the cover  114  and sealing the display area  101  from air and moisture. In smart electronic devices the display substrate  102  may additionally include a touch screen within the display area  101 . Alternatively a touch screen can be formed over the display substrate  102 . In the case of LCD display technology, a backlight  105  is located behind the display substrate. 
     Additional devices and IC chips  104  for operating the display module  100  are located off of the display substrate  102  on PCB  106 . For example, IC chips  104  can include a power management IC, processor, timing controller, touch sense IC, wireless controller, communications IC, etc. As illustrated, the PCB  106  is connected to the display substrate  102  with FPC  108 , with contact areas  107  of the FPC  108  bonded to surfaces of the display substrate  102  and PCB  106 . Referring to both  FIGS. 1A-1B , the area reserved on the display substrate for the one or more driver ICs  110  and contact area  107  are referred to as a contact ledge  111 . The PCB  106  may extend laterally from the display substrate  102 , or alternatively can be wrapped behind the display substrate as illustrated. As shown in  FIGS. 1A-1B , a lateral extension length  109  of the FPC  108  may be associated with the FPC  108  of the display module, even where the PCB  106  is wrapped behind the display substrate  102 . A battery  112  may also be located behind the display substrate with the PCB  106 . 
     COF packaging is similar to COG packaging, with one main difference being that the one or more driving ICs  110  are moved from the display substrate  102  onto the FPC  108 . In such applications, the contact ledge may require less space than COG packaging. 
     SUMMARY OF THE INVENTION 
     Display module packages and system applications thereof are described. In an embodiment, a display module includes a display substrate having a front surface, a back surface, and a display area on the front surface. A plurality of interconnects extend through the display substrate from the front surface to the back surface, and an array of LEDs are in the display area and electrically connected with the plurality of interconnects. One or more driver circuits are on the front surface or the back surface of the display substrate. In an embodiment, the plurality of interconnects extend through the display substrate from the front surface to the back surface directly behind the display area, and the one or more driver circuits are on the back surface of the display substrate. In an embodiment, a flexible printed circuit does not connect the one or more driver circuits to the display substrate. 
     The plurality of interconnects may be through vias that extend through the display substrate from the front surface to the back surface. The interconnects can be used for a variety of applications, for example, a ground via. A variety of devices can be located on the front or back surfaces of the display substrate. For example, a battery can be located on a back surface of the display substrate. In an embodiment, an array of micro chips are located on the front surface of the display substrate and within the display area. The array of micro chips may be electrically connected with the plurality of interconnects and the array of LEDs. In some embodiments, the array of micro chips overlaps the plurality of interconnects. In other embodiments, the array of micro chips do not overlap the plurality of interconnects. In an embodiment, the array of micro chips includes an array of ambient light sensors. A uniform distribution of ambient light sensors can be located in the array of micro chips. 
     In accordance with embodiments of the invention the display module can be incorporated into a wearable electronic device, for example, a smartwatch. In such an embodiment, the display area of the display substrate spans a watch face and a band of the smartwatch. In another embodiment, the display substrate is secured to a spool. In such an embodiment, the spool can include the one or more driver circuits in electrical contact with the plurality of interconnects. In one applications, the display module can be incorporated into a television. 
     In an embodiment, a non-transitory computer-readable medium stores instructions which, when executed by a processor, cause the processor to perform operations to adjust display data for a display area of a wearable electronic device. The operations include receiving input form a control device, with the input including data for the display area of the wearable electronic device. The input is parsed to derive the data for display, and the derived data is displayed on the display area, where the display area is on a flexible display substrate spanning a face and band of the wearable electronic device. For example, the wearable electronic device may be a smartwatch. In an embodiment, the non-transitory computer-readable medium stores additional instructions to perform additional operations including receiving a configuration of the display area of the watch face and band, receiving a design from the derived data, the design including a watch face and watch band, and updating the display area with the received design. 
     In an embodiment, a display module for a wearable electronic device includes a flexible display substrate spanning a face and a band of the wearable electronic device. An accessory manager is coupled to the display substrate, to receive input form a control device communicatively coupled to the display module. The display module additionally includes a graphical user interface (GUI) manager, to control information displayed on the display substrate, where the display substrate includes a first display area associated with a face of the wearable electronic device and a second display area associated with a band of the wearable electronic device. In an embodiment, the GUI manager is to further provide a watch face design to the first display area and a watch band design to the second display area. In an embodiment, the accessory manager is to further receive input data from a control device via a communication module, the input data including configuration data for the GUI manager. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a schematic cross-sectional side view illustration of a COG packaged display module. 
         FIG. 1B  is a schematic front view illustration of a COG packaged display module. 
         FIG. 2A  is a schematic cross-sectional side view illustration of a display substrate including a plurality of interconnects in accordance with an embodiment of the invention. 
         FIG. 2B  is a schematic cross-sectional side view illustration of a display substrate including a plurality of through vias in accordance with an embodiment of the invention. 
         FIG. 3  is a schematic cross-sectional side view illustration of a display substrate including an array of LEDs and micro chips in a display area on a front surface of the display substrate in accordance with an embodiment of the invention. 
         FIG. 4  is a schematic cross-sectional side view illustration of a display module including one or more driver circuits on the back surface of the display substrate directly behind the display area in accordance with an embodiment of the invention. 
         FIG. 5A  is a schematic front view illustration of a display substrate including an array of LEDs and micro chips in a display area and a plurality of through vias directly beneath the display area, where the array of micro chips overlap the plurality of through vias in accordance with an embodiment of the invention. 
         FIG. 5B  is a schematic back view illustration of a display substrate including one or more driver circuits on the back surface of the display substrate and a plurality of through vias directly behind the display area in accordance with an embodiment of the invention. 
         FIG. 5C  is a schematic front view illustration of a display substrate including an array of LEDs and micro chips in a display area and a plurality of through vias directly beneath the display area, where the array of micro chips do not overlap the plurality of through vias in accordance with an embodiment of the invention. 
         FIG. 5D  is a schematic front view illustration of a display substrate including an array of LEDs and micro chips in a display area and a plurality of through vias outside of the display area in accordance with an embodiment of the invention. 
         FIG. 6A  is a schematic cross-sectional side view illustration of TFT display substrate including one or more through vias in accordance with an embodiment of the invention. 
         FIG. 6B  is a schematic cross-sectional side view illustration of a TFT display substrate and display module including an array of LEDs in a display area and one or more through vias outside of the display area in accordance with an embodiment of the invention. 
         FIGS. 7A-7B  are schematic front view illustration of a TFT substrate and display module including one or more driver circuits in contact with one or more through vias outside of the display area in accordance with embodiments of the invention. 
         FIG. 8  is a schematic front view illustration of a TFT display substrate and display module including an array of LEDs and a plurality of through vias in accordance with an embodiment of the invention. 
         FIG. 9  is a schematic front view illustration of a wearable electronic device including a display panel in accordance with an embodiment of the invention. 
         FIGS. 10-12  are perspective view illustrations of a wearable electronic device displaying various display images in accordance with embodiments of the invention. 
         FIG. 13  is a system diagram of a wearable electronic device having a display panel in accordance with an embodiment of the invention. 
         FIG. 14  is schematic cross-sectional side view illustration of a system including a flexible display panel secured to a spool in accordance with an embodiment of the invention. 
         FIG. 15  is a schematic cross-sectional side view illustration of a flexible display panel including an array of LEDs and micro chips in a display area on a front surface of the display substrate in accordance with an embodiment of the invention. 
         FIG. 16  is a schematic front view illustration of a flexible display panel including two areas of micro chips exposed to different levels of ambient light in accordance with an embodiment of the invention. 
         FIG. 17  is a system diagram of a display system including the flexible display panel in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiments of the present invention describe display module packaging configurations and system applications thereof. In an embodiment, a display module includes a display panel which includes a display substrate with a front surface, a back surface, and a display area on the front surface. A plurality of interconnects extend through the display substrate from the front surface to the back surface, and are electrically connected with an array of LEDs are on the front surface of the display substrate. For example, each interconnect may be a single through via, or a series of interconnect lines and vias through multiple layers. One or more driver circuits are located on the front or back surfaces of display substrate and in electrical connection with the plurality of interconnects. In an embodiment the one or more driver circuits are located on the back surface of the display substrate. In an embodiment, the one or more driver circuits are located on the back surface of the display substrate directly behind the display area on the front surface of the display substrate. 
     In various embodiments, description is made with reference to figures. However, certain embodiments may be practiced without one or more of these specific details, or in combination with other known methods and configurations. In the following description, numerous specific details are set forth, such as specific configurations, dimensions and processes, etc., in order to provide a thorough understanding of the present invention. In other instances, well-known semiconductor processes and manufacturing techniques have not been described in particular detail in order to not unnecessarily obscure the present invention. Reference throughout this specification to “one embodiment” means that a particular feature, structure, configuration, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrase “in one embodiment” in various places throughout this specification are not necessarily referring to the same embodiment of the invention. Furthermore, the particular features, structures, configurations, or characteristics may be combined in any suitable manner in one or more embodiments. 
     The terms “spanning”, “over”, “to”, “between” and “on” as used herein may refer to a relative position of one layer with respect to other layers. One layer “spanning”, “over” or “on” another layer or bonded “to” or in “contact” with another layer may be directly in contact with the other layer or may have one or more intervening layers. One layer “between” layers may be directly in contact with the layers or may have one or more intervening layers. 
     In one aspect, embodiments of the invention enable the fabrication of display panels and display modules with a reduced form factor in the x-y and z directions compared to COG and COF display module packaging configurations. In an embodiment, the x-y and z form factors are reduced compared to COG and COF display module packaging configurations by connecting the one or more driver circuits to interconnects, for example through vias, extending through the display substrate from the front surface to the back surface rather than with a FPC. Furthermore, the packaging approaches in accordance with embodiments of the invention may improve system performance due to shorter interconnects between components. 
     In an embodiment, the x-y form factor (e.g. length-width) is reduced compared to COG and COF display module packaging configurations by removing or reducing the contact ledge area that would otherwise be reserved for one or more driver ICs  110  on the display area side of the display substrate, contact area of the FPC to the display substrate, and/or the lateral extension length associated with the FPC when positioned lateral to the display substrate  102  or wrapped around and below the display substrate. In accordance with embodiments of the invention, such a reduction of the x-y form factor may also allow for an increased allocation of display area on the display substrate. For example, COG packaging may require a contact ledge of at least 4-5 mm to allocate the driver ICs and FPC contact area. In accordance with embodiments of the invention, it is not required to allocate space for driver ICs and a FPC. In this manner a bevel width around the display area can be reduced below 1 mm, for example less than 0.5 mm. 
     In an embodiment, the z form factor (e.g. thickness) is reduced compared to COG and COF display module packaging configurations by removing the FPC and PCB. In accordance with embodiments of the invention, a plurality of interconnects, for example though vias, extend through the display substrate from the front surface to the back surface to connect the driver ICs and any additional IC chips including a power management IC, processor, timing controller, touch sense IC, wireless controller, communications IC, etc. In this manner, the chips and circuits for operating the display panel and module can be located on the back surface of the display substrate, eliminating the thickness of a PCB. In many embodiments, the driver ICs and additional IC chips are located directly behind the display area. 
     In some embodiments, the display panel includes a plurality of semiconductor-based LEDs in the display area. Such a configuration may enable the use of interconnects or through vias that otherwise may be problematic with the widely adopted LCD or OLED display technologies. For example, through vias and the placement of ICs on the back surface of the display substrate could be particularly problematic with conventional LCD technology which includes liquid crystals in the display area and requires the use of backlighting. Through vias could also be particularly problematic with existing OLED display technologies where through vias could potentially lead to air or moisture exposure. Though it is to be appreciated that some embodiments of the invention may be compatible with OLED display technology. 
     In another aspect, embodiments of the invention describe packaging configurations of flexible display panels into flexible display modules that can be incorporated into a variety of applications. In one application, embodiments of the invention describe a wearable electronic device, such as a smartwatch, including a flexible display panel and flexible display module. In this manner, the display area of the smartwatch is not limited to a rigid watch face area. In an embodiment, a smartwatch includes a flexible display panel that is integrated into a flexible watch band. Accordingly, curvature of the flexible display panel in both the watch face area and band may be adjusted to conform to the wrist size of the user. In addition, it is not required to include a FPC attached to the display area side of the display substrate. In this manner, the display area of the flexible display panel can cover more available space on the watch face area and band of the smartwatch. 
     The wearable electronic device may include a non-transitory computer readable medium including computer code for receiving a user input from a control device and adjusting display data for the display area of the wearable electronic device. For example, in one application, the user may select a specific watch design to be displayed on the display panel of the smartwatch spanning a watch face and band of the smartwatch. Upon receiving the user input from a control device such as a computer, or portable electronic device such as a smartphone, the display data for the display area of the wearable electronic device is adjusted. 
     In another application, the flexible display panel is rollable. For example, the display panel may be incorporated into a television display that is rollable or foldable into and out of a housing. In an embodiment, the flexible television display panel is coupled to a spool onto which the display panel is rollable or foldable. In an embodiment, the driver ICs and/or any additional IC chips including a power management IC, processor, timing controller, touch sense IC, wireless controller, communications IC, etc. can be relocated to the spool and electrically connected with the flexible television display panel with a redistribution layer on the back surface of the flexible television display panel. The driver ICs and any additional IC chips can alternatively be located on the back surface of the display panel. In another application, the flexible display panel is foldable. For example, the display panel may be incorporated into a smartphone or tablet and folded into various configurations. 
       FIG. 2A  is a schematic cross-sectional side view illustration of a display substrate including a plurality of interconnects in accordance with an embodiment of the invention. As illustrated, the display substrate  202  may include a front surface  203 , a back surface  205 , and a display area  201  on the front surface. A plurality of interconnects  204 ,  206  extend through the display substrate from the front surface  203  to the back surface  205  directly behind the display area  201 . As illustrated, each interconnect  204 ,  206  may be a series of interconnect lines  207 A and vias  207 B through multiple layers of a multi-layer display substrate  202 . Referring to  FIG. 2B , each interconnect  204 ,  206  may be a single through via formed through the display substrate  202 , which may be a single or multi-layer display substrate  202 . In interest of conciseness, the flowing description and figures refer to interconnect features  204 ,  206  as through vias. It is to be appreciated however, that such a configuration references an embodiment, and that when referring to through vias  204 ,  206 , these may be replaced by interconnects including a series of interconnect lines and vias through multiple layers of a multi-layer display substrate. Through vias  204 ,  206  may be formed using a variety of techniques including, but not limited to, chemical etching or laser drilling. 
     Display substrate  202  can be formed from a variety of materials including glass, amorphous silicon, polysilicon, single crystal silicon, metal foil, metal foil covered with dielectric, or a polymer such as poly(methyl methacrylate) (PMMA), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycarbonate (PC), polyethersulphone (PES), aromatic fluorine-containing polyarylates (PAR), polycyclic olefin (PCO), and polyimide (PI). In an embodiment, display substrate includes a polymer-silicon stack. In an embodiment, display substrate  202  is a flexible glass substrate. For example, display substrate  202  may be a flexible boro-silicate glass substrate. One exemplary flexible glass substrate is manufactured under the tradename WILLOW™ glass by Corning Incorporated located in Corning, N.Y. 
     In the embodiments illustrated, a redistribution layer  208  is formed on the back surface  205  of the display substrate. Redistribution layer may include a single layer or a plurality of layers including wiring  210 A,  210 B. For example, wiring  210 A can be used to for electrical contact with an array of LEDs formed on the top surface  203  of the display substrate  202  with one or more through vias  204 , while wiring  210 B may be used for a Vss connection with one or more through vias  206 . In an embodiment, the one or more through vias  204 ,  206  are directly behind the display area  201 . The one or more through vias  204 ,  206  may also be located outside of the display area  201 , such as along a periphery of the display area  201  on the top surface  203  of display substrate  202 . 
     A wiring layer  212  may also be located on the top surface  203  of display substrate  202  in electrical contact with the plurality of through vias  204 . Wiring layers  212 ,  210 A,  210 B and vias  204 ,  206  may be formed of any suitable electrically conductive material used in packaging applications including metals films, conductive polymers, conductive oxides, etc. Referring now to  FIG. 3 , in accordance with an embodiment of the invention and array of LED devices  214  and optionally micro chips  216  may be transferred and bonded to the display substrate  202 . For example, the array of LED devices  214  and micro chips  216  may be in electrical connection with the plurality of through vias  204 . 
     In accordance with embodiments of the invention, the LED devices  214  are semiconductor-based LED devices including one or more active layers (e.g. quantum well layers) between two doped semiconductor cladding layers. In the particular embodiments illustrated, the LED devices  214  are vertical LED devices in which the layers are horizontal, and the layers are stacked vertically. Top and bottom conductive contacts are formed on the vertical LED devices in order to make electrical contact with the top contact layers  220  described in further detail with regard to  FIG. 4  below and wiring layer  212 , respectively. In another embodiment, the LED devices  214  are horizontal LED devices in which the contacts to the doped cladding layers are both formed on the bottom surface of an LED device in order to make electrical contact with wiring layer  212 . 
     In accordance with embodiments of the invention, the micro chips  216  replace the TFT layer of a conventional active matrix display to switch and drive one or more LED devices  214 . In one embodiment, each micro chip  216  couples with one or more red, green, and blue led devices  214  that emit different colors of light. In such an exemplary red-green-blue (RGB) sub-pixel arrangement, each pixel includes three sub-pixels that emit red, green, and blue light. The RGB arrangement is exemplary and embodiments are not so limited. For example, alternative sub-pixel arrangements include red-green-blue-yellow (RGBY), red-green-blue-yellow-cyan (RBGYC), red-green-blue-white (RGBW), or other sub-pixel matrix schemes where the pixels have a different number of sub-pixels, such as displays manufactured under the trademark name PenTile™. In the exemplary embodiments illustrated in the following description, a single micro chip  216  is illustrated as controlling two pixels. It is to be appreciated that this configuration is likewise exemplary and embodiments are not so limited. For example, each micro chip  216  can switch and drive one or more LED devices  214  arranged in series, in parallel, or a combination of the two, such that multiple LED devices are driven from the same control signal. A variety of alternative configurations are contemplated in accordance with embodiments of the invention. In other embodiments, sensors such as touch sensors or light sensors can also be located on the front surface of the display substrate within the display area similarly as the micro chips. 
     In one aspect, embodiments of the invention describe display panels and display module packaging configurations in which micro LED devices and/or micro chips are transferred and bonded to a wiring  212  using an electrostatic transfer head assembly. In accordance with embodiments of the present invention, a pull-in voltage is applied to an electrostatic transfer head in order to generate a grip pressure on a micro LED device or micro chip. It has been observed that it can be difficult to impossible to generate sufficient grip pressure to pick up micro devices with vacuum chucking equipment when micro device sizes are reduced below a specific critical dimension of the vacuum chucking equipment, such as approximately 300 μm or less, or more specifically approximately 100 μm or less. Furthermore, electrostatic transfer heads in accordance with embodiments of the invention can be used to create grip pressures much larger than the 1 atm of pressure associated with vacuum chucking equipment. For example, grip pressures of 2 atm or greater, or even 20 atm or greater may be used in accordance with embodiments of the invention. Accordingly, in one aspect, embodiments of the invention provide the ability to transfer and integrate micro LED devices and micro chips into applications in which integration is not possible with current vacuum chucking equipment. In some embodiments, the term “micro” chip, “micro” LED device, or other “micro” structure may refer to the descriptive size, e.g. length or width, of certain devices or structures. In some embodiments, “micro” chips or “micro” LED devices may be on the scale of 1 μm to approximately 300 μm or less, or 100 μm or less in many applications. However, embodiments of the present invention are not necessarily so limited, and certain aspects of the embodiments may be applicable to larger micro devices or structures, and possibly smaller size scales. 
     Referring now to  FIG. 4 , following the transfer and bonding of the arrays of LEDs  214  and micro chips  216  a passivation layer  218  may be provided between the LEDs  214  and covering the wiring layer  212  followed by the deposition of a top contact layer  220 . In an embodiment, top contact layer  220  may be in electrical contact with a Vss line or Vss plane, for example that may be in electrical connection with the one or more through vias  206 . Alternatively the Vss line or Vss plane may be located on the top surface  203  of the display substrate  202 . Following the formation of top contact layer  220 , an encapsulation layer  222  may be formed over the display substrate. In some embodiments the encapsulation layer  222  may be a flexible encapsulation layer. 
     In accordance with embodiments of the invention, passivation layer  218  may be transparent or semi-transparent to the visible wavelength so as to not significantly degrade light extraction efficiency of the completed system. Passivation layer  218  may be formed of a variety of materials such as, but not limited to epoxy, poly(methyl methacrylate) (PMMA), benzocyclobutene (BCB), polyimide, and polyester. In an embodiment, passivation layer  218  is formed by ink jetting around the LEDs  214 . 
     Depending upon the particular application, top contact layer  220  may be opaque, reflective, transparent, or semi-transparent to the visible wavelength. For example, in top emission systems the top contact layer  220  may be transparent, and for bottom emission systems the top conductive contact may be reflective. Exemplary transparent conductive materials include amorphous silicon, transparent conductive oxides (TCO) such as indium-tin-oxide (ITO) and indium-zinc-oxide (IZO), carbon nanotube film, or a transparent conductive polymer such as poly(3,4-ethylenedioxythiophene) (PEDOT), polyaniline, polyacetylene, polypyrrole, and polythiophene. In an embodiment top conductive contact layer  220  is approximately 50 nm-1 μm thick ITO-silver-ITO stack. In an embodiment, the top conductive contact layer  220  includes nanoparticles such as silver, gold, aluminum, molybdenum, titanium, tungsten, ITO, and IZO. In a particular embodiment, the top conductive contact  220  is formed by ink jetting. Other methods of formation may include chemical vapor deposition (CVD), physical vapor deposition (PVD), spin coating. 
     In embodiments where top conductive layer  220  is transparent, the top encapsulation layer  222  may also be transparent or semi-transparent so as to not degrade light extraction efficiency of the system. Top encapsulation layer  222  may be formed of a variety of materials such as, but not limited to, silicon oxide (SiO 2 ), silicon nitride (SiN x ), poly(methyl methacrylate) (PMMA), benzocyclobutene (BCB), polyimide, and polyester, and may be formed by a variety of methods including chemical vapor deposition (CVD), physical vapor deposition (PVD), spin coating. 
     Still referring to  FIG. 4 , in accordance with embodiments of the invention, driver ICs  230  and additional devices and IC chips  234  for operating the display module  200  are located on the back surface  205  of the display substrate  102  of the display panel  215 . For example, IC chips  234  can include a power management IC, processor, memory, timing controller, touch sense IC, wireless controller, communications IC, etc. As illustrated, the driver ICs  230  and additional IC chips  234  may be located on the back surface of the display substrate directly behind the display area  201 . In one embodiment, a battery  238  may also be formed on RDL  208  on the back surface  205 , or alternatively a thin film battery  238  can be formed on the array of IC chips  230 ,  234 . 
     In an embodiment, the driver ICs  230  are in electrical connection with wiring  210 A in RDL  208 , which are in electrical connection with interconnects illustrated as through vias  204  extending between the front surface and back surface of the display substrate  202 , which are in electrical connection with wiring layer  212  on the top surface of display substrate  202 , which is in electrical connection with the LEDs  214  and optional micro chips  216 . In an embodiment wiring layer  212  includes scan lines, which are coupled to one or more scan driver ICs  230 , and data lines which are coupled to one or more data driver ICs  230  located on the back surface  205  of the display substrate  202  through vias  204 . The LEDs  214  may each be coupled to a common Vss through a through via  206 , or a plurality of through vias  206 . 
       FIG. 5A  is a schematic front view illustration of a display substrate  202  including an array of LEDs  214  and micro chips  216  in a display area and a plurality of through vias  204 ,  206  directly beneath the display area, where the array of micro chips overlap the plurality of through vias in accordance with an embodiment of the invention. As shown in  FIG. 5A , the display area  201  may include the entire surface of display substrate  202 , or at least the maximum amount of surface possible for placing the LEDs and micro chips. Through vias  204  may be connected to any of the chips  230 ,  234  on the back surface of the display substrate  202 . For example, through vias  204  may connect a micro chip  216  to a data line, scan line, Vdd, clock, etc. In the particular embodiment illustrated through vias  204  are directly beneath the array of micro chips  216 , and Vss through vias  206  are interspersed through the display area between the micro chips  216 .  FIG. 5B  is a schematic back view illustration of a display substrate  202  including one or more driver circuits  230  on the back surface of the display substrate and a plurality of through vias  204 ,  206  directly behind the display area in accordance with an embodiment of the invention. As shown a number of additional IC chips  234  and battery  238  may also be located directly behind the display area. 
       FIG. 5C  is schematic front view illustration of a display substrate including an alternative arrangement of an array of LEDs and micro chips in a display area  201  and a plurality of through vias directly beneath the display area  201 , where the array of micro chips  216  do not overlap the plurality of through vias  204 ,  206  in accordance with an embodiment of the invention. For example, the plurality of through vias  204 ,  206  can be interspersed between the micro chips  216  as illustrated in  FIG. 5C . In the exemplary embodiment illustrated in  FIG. 5C , wiring  212  is illustrated connecting the plurality of through vias  204  and LEDs  214  to the array of micro chips  216 . 
       FIG. 5D  is a schematic front view illustration of a display substrate including an array of LEDs and micro chips in a display area  201  and a plurality of through vias outside of the display area  201  in accordance with an embodiment of the invention. As shown in  FIG. 5D , the display area  201  may be smaller than the front surface of display substrate  202 , and the plurality of through vias  204 ,  106  are located along a periphery of the display substrate  202  outside of the display area  201 . In the exemplary embodiment illustrated in  FIG. 5D , wiring  212  has not been illustrated for connecting the plurality of through vias  204  to the micro chips  216  in order to not obscure the illustration. 
     Referring now to  FIGS. 6A-8 , the packaging configurations in accordance with embodiments of the invention are applied to an existing OLED display panel  315  to form a display module  300 . In the embodiment illustrated in  FIG. 6A , a display substrate  302  is a TFT backplane including working circuitry  316  and organic LEDs  314 . Exemplary TFT working circuitries  316  may include amorphous-silicon based, poly-silicon based, and indium-gallium-zinc-oxide based technologies. In an embodiment, through vias  304  can be formed through the display substrate in the contact ledge area  311  that is conventionally reserved for driver ICs and a FPC. Referring now to  FIG. 6B , similar to the previous embodiments described and illustrated, additional devices and IC chips  334  for operating the display module  300  are located on the back surface  305  of the display substrate  302 . For example, IC chips  334  can include a power management IC, processor, memory, timing controller, touch sense IC, wireless controller, communications IC, etc. As illustrated, the additional IC chips  334  may be located on the back surface of the display substrate directly behind the display area  301 . In the embodiment illustrated in  FIG. 7A , a driver IC  330  is located on the front surface  303  of the display substrate  302 . The driver IC  330  may be in electrical connection with the through vias  304  which in turn are in electrical communication with the wiring  310  in RDL  308  on the back surface  305  of the display substrate  302 . In the embodiment illustrated in  FIG. 7B , a driver IC  330  is located on the back surface  305  of the display substrate  302 , and in electrical communication with the through vias  304 . In the embodiment illustrated in  FIG. 7A , the driver ICs  330  are formed on the top surface of the display substrate  302  reserved for the contact ledge  311 . In the embodiment illustrated in  FIG. 7B , the drive IC  330  is at least partially located directly behind the display area  301 . In either configuration, the driver IC  330  communicates with the working circuitry  316  similarly as with a conventional OLED display. 
       FIG. 8  is a schematic front view illustration of a TFT display substrate and display module including an array of LEDs and a plurality of through vias in accordance with an embodiment of the invention. The particular embodiment illustrated in  FIG. 8  is similar to that previously illustrated in  FIG. 4 , with a TFT display substrate including working circuitry  316  replacing micro chips  216 . In an embodiment, through vias  304  can be formed through the display substrate directly behind the display area  301 . 
       FIG. 9  is a schematic front view illustration of a wearable electronic device including a display panel in accordance with an embodiment of the invention. The wearable electronic device  400  may be any of a number of wearable accessory products that include a display panel  215 ,  315 , and in particular a flexible display panel  215 ,  315 . The flexible display panel  215 ,  315  may be formed in any of the display modules described above. In an embodiment, the flexible display panel  215 ,  315  does not include a contact ledge  111 , which may allow for increased allocation space to the display area  201 . 
     In one embodiment, the wearable electronic device is a smartwatch including a watch face  402 , band  404 , and clasp  406 . A flexible display panel  215 ,  315  may be integrated into the smartwatch so that it spans both the watch face and band. In this manner, the flexible display panel  215 ,  315  can be adjusted to the contour of a user&#39;s arm. In accordance with embodiments of the invention, a bezel  410  width surrounding the display panel  215 ,  315  can be minimized, for example below 4-5 mm or even less than 1 mm, less than 0.5 mm, or eliminated. Thus, the bezel  210  design of the smartwatch can be designed for aesthetic concerns rather than as a requirement for allocating space for a contact ledge. 
       FIGS. 10-12  are perspective view illustrations of a wearable electronic device displaying various display images in accordance with embodiments of the invention. In the embodiment, illustrated in  FIG. 10 , the wearable electronic device  400  is illustrated with a blacked out display area of the display panel  215 ,  315 . For example, this may indicate a state in which the display panel is turned off.  FIGS. 11-12  illustrate states of where the display panel is displaying different images. For example,  FIG. 11  may display a watch design A, including watch face and band and  FIG. 12  may display a watch design B, including a watch face and band. Any number of displayed images are possible. 
       FIG. 13  illustrates a system diagram of an embodiment of wearable display module  1300 . For example, the wearable display module  1300  may be incorporated into the wearable electronic devices of  FIGS. 10-12 , and include any of the flexible display panels described herein. The module  1300  includes a processor  1302  and memory  1303  for managing the wearable electronic devices and executing or interpreting instructions and commands for the wearable electronic devices. The processor  1302  can be a general-purpose processor or a microcontroller for controlling the wearable electronic devices. The memory  1303  can be integrated within the processor  1302 , or coupled to the processor  1302  via a memory bus. The memory  1303  includes nonvolatile storage, such as flash memory, and can additionally include read only memory (ROM), and a form of volatile random access memory (RAM). In one embodiment, the processor  1302  includes media decode capability, to display encoded content via a flexible display panel  1304 . In one embodiment, the module  1300  includes a graphical user interface (GUI) manager  1306 , to control information that is provided to and displayed on the flexible display panel  1304 . 
     The module  1300  also includes a communication module  1308  that facilitates communication between the module  1300  and other electronics. In one embodiment, the communication module  1308  includes a module to provide connectivity via universal serial bus (USB). The communication module  1308  can further include wireless transceivers for Bluetooth, or WLAN connectivity, and can additionally include one or more WWAN transceivers to communicate with a wide area network including a cellular data network. 
     In one embodiment, the module  1300  includes an accessory manager  1310  that operates to authenticate and acquire data from an additional electronic device that can be coupled to the module  1300 . In one embodiment, the module  1300  is an accessory to a primary display device, and the accessory manager  1310  facilitates the connection of the additional electronic device to the module  1300 . In one embodiment, the module  1300  may have accessory devices that are managed by the accessory manager  1310 , which facilitates the transfer of data to and from accessory devices. 
     In an embodiment, memory  1303  includes non-transitory computer-readable medium stores instructions which, when executed by processor  1302 , cause the processor to perform operations to adjust display data for a flexible display panel  1304  of the module  1300 . In an embodiment, the operations including receiving input from a control device, the input including data for the flexible display panel, parsing the input to derive the data for display, and displaying the derived data on the flexible display panel. In an embodiment, the operations further include receiving a configuration of the flexible display panel of the watch face and band, receiving a design from the derived data, (e.g. type of watch design including a watch face and watch band), and updating the flexible display panel spanning the watch face and watch band of the smartwatch with the received design. 
     In an embodiment, an accessory manager is coupled to the flexible display substrate  1304  to receive input from a control device communicatively coupled to the module  1300 . A graphical user interface (GUI) manager is coupled to the display substrate, to control information displayed on the display substrate, where the display substrate includes a first display area associated with a face of the wearable electronic device and a second display area associated with a band of the wearable electronic device. In an embodiment, the GUI manager provides a watch face design to the first display area and a watch band design to the second display area. In an embodiment, the accessory manager receives input data from a control device via a communication module, the input data including configuration data for the GUI manager. 
       FIG. 14  is schematic cross-sectional side view illustration of a system  1400  including a flexible display panel  1500  secured to a spool  1410  in accordance with an embodiment of the invention.  FIG. 15  is a schematic cross-sectional side view illustration of a flexible display panel  1500  including an array of LEDs  214  and micro chips  216  in a display area on a front surface  203  of the display substrate  202  in accordance with an embodiment of the invention. The display panel  1500  illustrated in  FIGS. 14-15  may be similar to any of the display panels previously described above. In the embodiment illustrated in  FIGS. 14-15 , the flexible display panel  1500  is rollable into and out of a housing  1420 . In such an embodiment, rather than locating the driver ICs  1430  additional IC chips  1434  and battery  1438  on the back surface  205  of the display substrate  202 , any combination of these components can be located within the housing  1420 , such as on the spool  1410 . In other embodiments, any of these components may also be located on the back surface  205  of the display substrate. For example, a thin film battery  1438  can be located on the back surface, or a plurality of batteries  1438  can be located on the back surface. Likewise one or more driver ICs  1430  may be located on the back surface to reduce transmission line distance to the micro chips  216 . 
     In an embodiment, the micro chips  216  may include ambient light sensors to measure the ambient light striking the display area of the flexible display panel  1500 . Referring to  FIG. 16 , a schematic front view illustration is provided of a flexible display panel  1500  including two areas of micro chips  216 A,  216 B exposed to different levels of ambient light in accordance with an embodiment of the invention. In an embodiment, area  216 B of micro chips  216  is exposed to a greater amount of light than area  216 A, for example, glare from a window within a display room. In such an embodiment, a processor or ambient light controller in the system  1400  may increase the amount of light being emitted from the LEDs  214  operated by the micro chips  216  in area  216 B in order to compensate for the ambient light. 
       FIG. 17  illustrates a system diagram  1700  for an embodiment of a display system (e.g. a television) including a flexible display panel  1710  described herein, including the system and display panels described with regard to  FIGS. 14-16 . The display system  1700  includes a processor  1720  and memory  1704  for managing the system and executing instructions. The memory includes non-volatile memory, such as flash memory, and can additionally include volatile memory, such as static or dynamic random access memory (RAM). The memory  1704  can additionally include a portion dedicated to read only memory (ROM) to store firmware and configuration utilities. In an embodiment, the processor  1720  manages ambient light correction of the flexible display panel  1710  by controlling each micro chip  216  output to LED devices  214  where light output is adjusted based on light sensor data from a sensor controller  1770 . Alternatively, such an ambient light correction module  1705  can be located on each of the micro chips  214  within the display panel  1710 . 
     The system also includes a power module  1780  (e.g., flexible batteries, wired or wireless charging circuits, etc.), a peripheral interface  1708 , and one or more external ports  1790  (e.g., Universal Serial Bus (USB), HDMI, Display Port, and/or others). In one embodiment, the display system  1700  includes a communication module  1712  configured to interface with the one or more external ports  1790 . For example, the communication module  1712  can include one or more transceivers functioning in accordance with IEEE standards, 3GPP standards, or other communication standards, and configured to receive and transmit data via the one or more external ports  1790 . The communication module  1712  can additionally include one or more WWAN transceivers configured to communicate with a wide area network including one or more cellular towers, or base stations to communicatively connect the display system  1700  to additional devices or components. Further, the communication module  1712  can include one or more WLAN and/or WPAN transceivers configured to connect the electronic device  1700  to local area networks and/or personal area networks, such as a Bluetooth network. 
     The display system  1700  can further include a sensor controller  1770  to manage input from one or more sensors such as, for example, proximity sensors, ambient light sensors, or infrared transceivers. In an embodiment, the array of micro chips  216  on the display panel includes an array of light sensors in communication with the sensor controller. Each micro chip  216  may include a light sensor, or only portion of the array of micro chips includes light sensors. For example, the array of light sensors can be uniformly distributed in the array of micro chips. In one embodiment the system includes an audio module  1731  including one or more speakers  1734  for audio output and one or more microphones  1732  for receiving audio. In embodiments, the speaker  1734  and the microphone  1732  can be piezoelectric components. The electronic device  1700  further includes an input/output (I/O) controller  1722 , a display screen  1710 , and additional I/O components  1718  (e.g., keys, buttons, lights, LEDs, cursor control devices, haptic devices, and others). The display device/screen  1710  and the additional I/O components  1718  may be considered to form portions of a user interface (e.g., portions of the display system  1700  associated with presenting information to the user and/or receiving inputs from the user). 
     In utilizing the various aspects of this invention, it would become apparent to one skilled in the art that combinations or variations of the above embodiments are possible for forming flexible display panels and system applications including the flexible display panels. Although the present invention has been described in language specific to structural features and/or methodological acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. The specific features and acts disclosed are instead to be understood as particularly graceful implementations of the claimed invention useful for illustrating the present invention.

Metadata:
Filing Date: 20191119
Publication Date: 20210323
Grant Date: 20210323
Priority Date: 20131217
Inventors: BIBL, ANDREAS
SAKARIYA, KAPIL V.
PAVATE, VIKRAM
Assignee: APPLE INC
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