Abstract:
A first wiring board, which is a flexible printed-circuit board, is bonded to a second wiring board. A plurality of protruding member are formed on the surface of the second wiring board. An adhesive is deposited on the surface of the second wiring board such that there is a thinner layer of the adhesive on the protruding member than in other areas. Subsequently, the first wiring board is placed on the second wiring board so that a portion of the first wiring board to be used for the wire-bonding is positioned above at least one of the protruding members. The first wiring board gets bonded to the second wiring board due to the adhesive.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a technology for bonding a flexible printed-circuit board to another printed circuit board. 
         [0003]    2. Description of the Related Art 
         [0004]    Recently, there is an increasing demand for reducing a size and improving a design flexibility of small electronic devices such as cellular telephones. To satisfy such a demand, flexible printed-circuit (FPC) boards have been widely used, in addition to the conventional electronic printed-circuit boards made of an electric insulating material such as glass epoxy that has been used for a long time. In the FPC board, a printed circuit board, which is a wiring pattern, is provided on the surface of or inside a flexible resin film. 
         [0005]    When the electronic printed-circuit board and the FPC board are used together, electronic parts and/or wiring of the electronic printed-circuit board needs to be electrically connected to the FPC. If the circuit boards are designed for a relatively large electronic device, the device has enough space to fix the electronic printed-circuit board and the FPC board by using, i.e., fittings, and to connect the electronic printed-circuit board and the FPC board through, i.e., lead wires. 
         [0006]    On the other hand, because a small electronic device cannot afford such space required for the fixation and the connection, the electronic printed-circuit board and the FPC board are often bonded using, i.e., an adhesive, and connected together by performing wire-bonding between the electronic parts of the electronic printed-circuit board and the FPC board. For example, Japanese Patent Application Laid-open No. H6-275931 discloses a technology for improving productivity that is otherwise to be lowered due to a contact failure and realizing a reliable wire-bonding, by adjusting the thickness of the material of the FPC board when the wire-bonding is performed between the electronic parts and the FPC board. 
         [0007]    However, according to the disclosed technologies, problems caused by the adhesive are not considered. To perform the wire-bonding, an ultrasonic wire-bonding method is generally used, with which wires and an object is bonded by applying ultrasonic vibration to the wires made of, i.e., gold, and using friction generated between the wires and the object to be connected to the wires. The contact effect can be improved by applying heat to the object to be bonded to the wires. 
         [0008]    Thus, when the wire-bonding is performed on the FPC board adhered to the electronic printed-circuit board, it is important to sufficiently apply ultrasound waves and heat to a contact portion. However, if the adhesive layer that bonds the electronic printed-circuit board and the FPC board is relatively thick, the layer absorbs the ultrasonic vibration and prevents the heat from properly flowing to the contact portion, which causes a connection failure. On the other hand, if the adhesive layer is relatively thin, the fixation strength is weakened, which increases the risk of the FPC board coming off from the electronic printed-circuit board. 
       SUMMARY OF THE INVENTION 
       [0009]    It is an object of the present invention to at least partially solve the problems in the conventional technology. 
         [0010]    According to an aspect of the present invention, a flexible printed-circuit boards bonding method for bonding a first wiring board that is formed of a flexible printed-circuit board and a second wiring board that is to be electrically connected to the first wiring board by wire-bonding, the flexible printed-circuit boards bonding method includes forming a plurality of protruding member on a surface of the second wiring board, depositing an adhesive on the surface of the second wiring board such that there is a thinner layer of the adhesive on the protruding member than in other areas, and placing, after the depositing, the first wiring board on the second wiring board so that a portion of the first wiring board to be used for the wire-bonding is positioned above at least one of the protruding members thereby bonding the first wiring board to the second wiring board with the adhesive. 
         [0011]    According to another aspect of the present invention, a printed circuit board in which a first wiring board formed of a flexible printed-circuit board and a second wiring board to be electrically connected to the first wiring board by wire-bonding are bonded, the printed circuit board includes a protruding member arranged on a surface of the second wiring board, and an adhesive layer arranged on the protruding member and the surface of the second wiring board and that bonds the first wiring board and the second wiring board, wherein the adhesive layer is thinner on the protruding member than in other areas. 
         [0012]    The above and other objects, features, advantages and technical and industrial significance of this invention will be better understood by reading the following detailed description of presently preferred embodiments of the invention, when considered in connection with the accompanying drawings. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a side view for explaining an electrical connection between an electronic printed-circuit board and an FPC board according to an embodiment of the present invention; 
           [0014]      FIG. 2  is a top view of the electronic printed-circuit board and the FPC board shown in  FIG. 1 ; 
           [0015]      FIG. 3  is a top view of an electronic printed-circuit board and an FPC board according to another embodiment of the present invention; 
           [0016]      FIG. 4  is a top view of an electronic printed-circuit board and an FPC board according to still another embodiment of the present invention; 
           [0017]      FIG. 5  is a flowchart of a flexible printed-circuit boards bonding method according to still another embodiment of the present invention; 
           [0018]      FIG. 6  is a side view for explaining a first step of the flexible printed-circuit boards bonding method; 
           [0019]      FIG. 7  is a side view for explaining a second step of the flexible printed-circuit boards bonding method; 
           [0020]      FIG. 8  is a side view for explaining a third step of the flexible printed-circuit boards bonding method; 
           [0021]      FIG. 9  is a side view for explaining a completed state obtained by the flexible printed-circuit boards bonding method; and 
           [0022]      FIG. 10  is a side view for explaining an electrical connection between an electronic printed-circuit board and an FPC board by performing wire-bonding, through a conventional flexible printed-circuit boards bonding method. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0023]    Exemplary embodiments of the present invention will be explained below in detail with reference to the attached drawings. 
         [0024]    An explanation of a conventional flexible printed-circuit boards bonding method will be given first.  FIG. 10  is a side view for explaining an electrical connection between an electronic printed-circuit board  20 , and an FPC board  101  by performing wire-bonding, which are bonded together through the conventional flexible printed-circuit boards bonding method. 
         [0025]    As shown in  FIG. 10 , the FPC board  101  and the electronic printed-circuit board  20 , are bonded together with an adhesive  30  and the resultant structure is arranged on a wire bonder stage  40 . Thereafter, a wire  50  is brought into contact with a bonding pad  13  of the FPC board  101  by the wire-bonding to establish an electrical connection between the FPC board  101  and the electronic printed-circuit board  201 . 
         [0026]    The FPC board  101  is a printed circuit board in which wiring  12  is arranged on a flexible insulating film  11 . The bonding pad  13 , which serves as a terminal that is to be connected to the wire  50  by the wire-bonding, is provided on one end portion of the wiring  12 . Various electronic parts can be mounted on the FPC board  101 , although they are not shown. 
         [0027]    The electronic printed-circuit board  20 , is a printed circuit board in which wiring  22  is arranged on a board  21  made of an electrical insulating material such as glass epoxy. Various electronic parts can be mounted on the electronic printed-circuit board  201 , although they are not shown. The wire bonder stage  40  is a horizontally movable table, on which an object to be wire-bonded is placed. 
         [0028]    The adhesive  30  bonds the FPC board  101  and the electronic printed-circuit board  20 , together, forming a layer between the FPC board  101  and the electronic printed-circuit board  201 . The thickness of the layer can vary, depending on the amount of the adhesive  30  coated in the bonding process. In general, an adhesive has properties of high vibration absorption and low thermal conductivity. Therefore, the thickness of the layer of the adhesive  30  largely affects the reliability of the wire-bonding. 
         [0029]    More specifically, when ultrasound is applied on top of the bonding pad  13  and heat is applied from beneath the bonding pad  13  through the board  21  and the adhesive  30  for performing the wire-bonding between the wire  50  and the bonding pad  13 , if the layer of the adhesive  30  is relatively thick, the adhesive  30  absorbs the ultrasonic vibration and prevents the heat from sufficiently conducting, which results in contact failure. The contact failure does not immediately lead to a break in wiring, but still causes problems such that contact resistance increases and reliability gets lowered in the long term. 
         [0030]    On the other hand, when the layer of the adhesive  30  is thin, because fixation strength reduces, there is a threat that the FPC board  101  comes off from the electronic printed-circuit board  201 . With the conventional flexible printed-circuit boards bonding method, as described above, it is difficult to prevent the layer of the adhesive  30  from absorbing ultrasound and lowering the heating efficiency and to ensure the fixation strength at the same time. 
         [0031]    Next, the flexible printed-circuit boards bonding method according to an embodiment of the present invention will be explained.  FIG. 1  is a side view for explaining an electrical connection between an electronic printed-circuit board  202  and the FPC board  101  by performing the wire-bonding, which are bonded together through the flexible printed-circuit boards bonding method according to an embodiment of the present invention. 
         [0032]    Even in  FIG. 1 , the FPC board  101  and the electronic printed-circuit board  20 , are bonded with the adhesive  30  and arranged on the wire bonder stage  40 . An electrical connection is established between the FPC board  101  and the electronic printed-circuit board  202  by performing the wire-bonding between the wire  50  and the bonding pad  13  of the FPC board  101 . 
         [0033]    As shown in  FIG. 1 , with the flexible printed-circuit boards bonding method according to the embodiment, hard and highly thermally conductive blocks  23   a  and  23   b , which are protruding members, are formed on the electronic printed-circuit board  202 , with which a convex surface is provided, so that the layer of the adhesive  30  is prevented from absorbing the ultrasound and lowering the heating efficiency, while a sufficient fixation strength is to be ensured. 
         [0034]    The blocks  23   a  and  23   b  are spaced apart from each other, and the adhesive  30  is supplied drop-by-drop in the space between the blocks  23   a  and  23   b . The FPC board  101  is bonded to the electronic printed-circuit board  202  in such a manner that the bonding pad  13  is placed exactly above either the block  23   a  or the block  23   b .  FIG. 1  depicts an example in which the bonding is performed so that the bonding pad  13  is placed exactly above the block  23   a.    
         [0035]    In the bonding process, the FPC board  101  is pressed against the electronic printed-circuit board  202 , and the excess of the adhesive  30  flows out through the gap between the blocks  23   a  and  23   b . As a result, the adhesive  30  is spread with a small thickness immediately under the bonding pad  13  and with a large thickness between the blocks  23   a  and  23   b.    
         [0036]    Because the portion of the layer of the adhesive  30  under the bonding pad  13  is thin, the ultrasonic vibration applied on top of the bonding pad  13  to perform the wire-bonding between the wire  50  and the bonding pad  13  generates sufficient friction without being absorbed by the layer of the adhesive  30 . In addition, the heat applied from beneath the bonding pad  13  through the board  21  and the adhesive  30  sufficiently flows to the contact portion, which improves the contact effect. 
         [0037]    Further, because the portion of the layer of the adhesive  30  between the blocks  23   a  and  23   b  is thick, the sufficient fixation strength is ensured in the bonding between-the FPC board  101  and the electronic printed-circuit board  202 . Therefore, according to the flexible printed-circuit boards bonding method of the embodiment, it is possible to prevent the layer of the adhesive  30  from absorbing the ultrasound and lowering the heating efficiency, and ensure the fixation strength at the same time. 
         [0038]    Because the FPC board  101  is supported by the blocks  23   a  and  23   b  during the bonding process, problems such that the FPC board  10 ; is to be bonded to the electronic printed-circuit board  202  in a tilted manner and the thicknesses of the adhesive  30  become different among different units can be prevented. 
         [0039]    Although the example of the two rectangular blocks  23   a  and  23   b  formed on the electronic printed-circuit board  202  is shown in  FIG. 1 , the number, shape, height, arrangement, and the like of the blocks can be changed as required, in accordance with the dimensions of the FPC board  101  and the required fixation strength. For instance, if the fixation strength needs to be set high, the spacing between the blocks  23   a  and  23   b  needs to be widened, and the height of the blocks needs to be increased. 
         [0040]    Further, the blocks  23   a  and  23   b  can be formed of any material as long as the material is hard and highly thermally conductive. For instance, the blocks  23   a  and  23   b  can be formed as part of the wiring pattern similar to the wiring  22 . In general, the wiring pattern on the electronic printed-circuit board  202  is formed by etching a thin copper film. Accordingly, by forming the blocks  23   a  and  23   b  as part of the wiring pattern, the targeted form can be achieved without adding an extra producing process. As the material, copper is preferable because the copper is hard and highly thermally conductive. 
         [0041]    In the example shown in  FIG. 1 , the electronic printed-circuit board  202  and the FPC board  101  are bonded to each other, and the wiring is individually connected through the wire-bonding. However, the flexible printed-circuit boards bonding method according to the embodiment is equally effective for connecting the wiring of printed circuit boards and electronic parts, or for connecting electronic parts together, by the wire-bonding. In addition, the flexible printed-circuit boards bonding method according to the embodiment is equally effective for bonding the FPC boards and performing the wire-bonding of the wiring or the like provided on wiring boards. 
         [0042]      FIG. 2  is a top view of the electronic printed-circuit board  202  and the FPC board  101  shown in  FIG. 1 . In  FIG. 2 , the wiring  12  includes three wires of  12   a  to  12   c , which are substantially parallel to one another. In a similar manner, the bonding pad  13  includes three bonding pads  13   a  to  13   c  and the wiring  22  includes three wiring  22   a  to  22   c.    
         [0043]    As shown in  FIG. 2 , an excess amount of the adhesive  30  flows out between the blocks  23   a  and  23   b  onto the electronic printed-circuit board  202 . When the portion of the layer of the adhesive  30  beneath the bonding pad  13  is made to be thin and the adhesive  30  is to be sufficiently filled in the space between the blocks  23   a  and  23   b , the excess amount of the adhesive  30  flows onto the electronic printed-circuit board  202 . 
         [0044]    The excess of the adhesive  30  covers electronic parts on the electronic printed-circuit board  202  and causes defects such that the electronic parts cannot be connected to other electronic parts. To avoid such defects, according to another embodiment of the present invention, blocks similar to the blocks  23   a  and  23   b  are arranged onto the electronic printed-circuit board  202  to control the flow of the excess of the adhesive  30 . 
         [0045]      FIG. 3  is a top view for explaining an example of additional blocks provided to control the flow of the excess of the adhesive  30 . In  FIG. 3 , blocks  23   c  and  23   d  are arranged on an electronic printed-circuit board  203  in such a manner as to fill the gap between the blocks  23   a  and  23   b , so that the excess of the adhesive  30  cannot flow toward electronic parts  24  and  25  on the electronic printed-circuit board  203 . 
         [0046]    Through the arrangement of the blocks, the flow of the excess of the adhesive  30  can be controlled, and defects caused by the flow can be avoided. The arrangement of the blocks  23   a  to  23 d shown in  FIG. 3  is one example, and arrangement, the number, shape, height, and the like of the blocks can be determined as required in accordance with the intended way of controlling the flow of the excess. 
         [0047]    For example, if it is required to prevent the excess of the adhesive  30  from flowing in a specific direction, the blocks can be arranged with a space between the blocks so that the excess of the adhesive  30  can flow in a different direction. Thus, by discharging the excess of the adhesive  30  without affecting the electronic parts of the electronic printed-circuit board  203  and the like, it is possible to prevent the differences of the layer thickness of the adhesive  30  among the different units caused by the amounts of the dropping of the adhesive  30 . 
         [0048]    On the other hand, to completely stop the excess from flowing out, the blocks can be arranged in such a manner as to have no spacing between the blocks. When the adhesive  30  has a low viscosity, it is effective to narrow down the spacing between the blocks for blockading the excess. When the adhesive  30  has a high viscosity, the excess does not flow out as much, even if the spacing between the blocks is set wider. 
         [0049]    The flow of the excess of the adhesive  30  can as well be controlled by other methods. As still another embodiment of the present invention,  FIG. 4  is a top view for explaining an example of controlling the flow of the excess of the adhesive  30  by forming holes in an FPC board  102 . 
         [0050]    In  FIG. 4 , several holes  14  are formed in the film  11  of the FPC board  102 , and the blocks  23   a ,  23   b ,  23   e , and  23   f  are placed on an electronic printed-circuit board  204  in such a manner to have no spacing between the blocks. Accordingly, the excess of the adhesive  30  flows out through the holes  14  onto the FPC board  102  and does not flow to reach the electronic parts  24  and  25 , in the process of bonding the FPC board  102  and the electronic printed-circuit board  204 . 
         [0051]    As described above, by forming holes in the FPC board  102 , the flow of the excess of the adhesive  30  can be controlled and an occurrence of the defects caused by the flow can be prevented. Further, by discharging the excess of the adhesive  30  toward the top of the FPC board  102 , the layer of the adhesive  30  attains a uniform thickness among units regardless of the supply amount of the adhesive  30 . The process performed on the FPC board  102  shown in  FIG. 4  is one example and the number, shape, arrangement, size, and the like of the holes  14  can be determined in accordance with the required fixation strength, the viscosity of the adhesive  30 , and the like. 
         [0052]    Next, the processing procedure of the flexible printed-circuit boards bonding method according to still another embodiment the present invention is explained through an example of bonding the FPC board  101  and the electronic printed-circuit board  202  shown in  FIG. 1 .  FIG. 5  is a flowchart of the processing procedure for an operation of the flexible printed-circuit boards bonding method according to the embodiment. 
         [0053]    The blocks  23   a  and  23   b  are formed on the board  21  of the electronic printed-circuit board  202  as shown in  FIG. 6  (Step S 101 ). The blocks  23   a  and  23   b  can be formed at the same timing of forming the wiring  22 , or at a different timing from forming the wiring  22 . A predetermined amount of the adhesive  30  is supplied in drops onto an area between the blocks  23   a  and  23   b  as shown in  FIG. 7  (Step S 102 ). 
         [0054]    The FPC board  101  is pressed against the board  21  with vibration of the FPC board  101  in a microscale in a horizontal direction with respect to the bonding surface, and the position of the FPC board  101  is determined so that the bonding pad  13  on the FPC board  101  is placed above the block  23   a  as shown in  FIG. 8  (Step S 103 ). The FPC board  101  has to be vibrated in a microscale so that the adhesive  30  properly spreads through the space surrounded by the FPC board  101 , the board  21 , and the blocks  23   a  and  23   b , from corner to corner. 
         [0055]    After the positioning is determined and the excess of the adhesive  30  is discharged by sufficiently pressing the FPC board  101  against the electronic printed-circuit board  202 , the adhesive  30  is stabilized. In this manner, the bonding of the FPC board  101  and the electronic printed-circuit board  202  is completed as shown in  FIG. 9  (Step S 104 ). 
         [0056]    As described above, according to the embodiments, it is configured in such a manner that, by arranging the blocks on the electronic printed-circuit board, the layer of the adhesive has a thin portion at the position where the wire-bonding is performed on the flexible printed-circuit board, while the remaining portion of the layer is made sufficiently thick. Thus, degradation of the bonding effect of the adhesive can be prevented and the wire-bonding effect can be enhanced, while the sufficient fixation strength can be ensured at the same time. 
         [0057]    According to one aspect of the present invention, a portion of an adhesive layer where a wire-bonding process is to be performed onto a flexible printed-circuit board is made thinner than the remaining portion of the adhesive layer. Accordingly, it is possible to prevent the adhesive from reducing the connection effect, to maintain sufficient fixation strength, and to improve the connection effect obtained by the wire-bonding. 
         [0058]    Furthermore, according to another aspect of the present invention, the blocks that support the flexible printed-circuit board at the time of bonding prevent the flexible printed-circuit board from being bonded in a tilted manner to the second wiring board and prevent the thickness of the adhesive layer from varying from one unit to another. 
         [0059]    Moreover, according to still another aspect of the present invention, the blocks are formed as a portion of the wiring pattern so that the block formation can be realized without adding an extra processing step. 
         [0060]    Furthermore, according to still another aspect of the present invention, the blocks are formed in such a shape as to stop an excess amount of the adhesive from flowing out. Therefore, the flown-out excessive adhesive does not affect the wiring or parts of the wiring boards. 
         [0061]    Moreover, according to still another aspect of the present invention, the blocks are formed into such a shape as to control the flowing direction of the excess amount of the adhesive to be discharged. Accordingly, it is possible to prevent the formation of the adhesive layer from varying in accordance with the amount of the dropping of the adhesive, and to prevent the flown-out excess of the adhesive from affecting the wiring and parts on the wiring boards. 
         [0062]    Furthermore, according to still another aspect of the present invention, the spacing between the blocks is adjustable in accordance with the fixation strength that is required. Thus, a reliable printed circuit board with the sufficient fixation strength can be achieved. 
         [0063]    Moreover, according to still another aspect of the present invention, the height of the blocks is adjustable in accordance with the fixation strength that is required. Thus, a reliable printed circuit board with the sufficient fixation strength can be achieved. 
         [0064]    Furthermore, according to still another aspect of the present invention, the spacing of the blocks is set small when the adhesive has a low viscosity. Accordingly, the excess of the adhesive can be prevented from flowing out, resulting in not causing an effect on the wiring and the parts on the wiring boards. 
         [0065]    Moreover, according to still another aspect of the present invention, the flexible printed-circuit board is bonded to the second wiring board, with vibration of the circuit board. In this manner, the adhesive can spread corner to corner of the area-surrounded by the wiring board and the blocks. 
         [0066]    Furthermore, according to still another aspect of the present invention, holes are formed in the flexible printed-circuit board to discharge the excess amount of the adhesive. Therefore, while the flown-out excess of the adhesive is prevented from affecting the wiring and the parts on the wiring board, the uniformity in the adhesive layer can be attained, regardless of the amount of the dropping of the adhesive. 
         [0067]    Although the invention has been described with respect to a specific embodiment for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth.