Patent Publication Number: US-2017365945-A1

Title: Edge assembly for attaching to flexible substrates

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 62/087,089 filed Dec. 3, 2014, which is herein incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to electronic assemblies, and more specifically, to an assembly including at least an interface that may be attached to an edge of a flexible substrate. 
     BACKGROUND 
     Electronics manufacturing typically uses circuit board materials such as, for example, polytetrafluoroethylene (Teflon), or composite materials like FR-4, FR-1, CEM-1 or CEM-3. At least one limitation in these materials is their rigidity. Rigidity is not a problem when devices are relatively large and flat. However, the miniaturization of devices, the advent of devices that have non-uniform shape including, for example, curved monitors, wearable devices, etc. has made this characteristic of traditional circuit board materials more of an issue. At least one solution to this problem may lie in flexible substrates. Flexible substrates employing, for example, polyethylene terephthalate (PET) may provide a surface to which electronic components may be mounted that may be bent, twisted, flexed, etc. without affecting the performance of the circuitry. Electronics may then be designed to accommodate applications not serviceable utilizing traditional materials. 
     While flexible substrates may grant design flexibility, flexible substrates must also be able to integrate with existing systems. Most systems will not use flexible substrates exclusively, and thus, must include a way to, for example, mount flexible substrates into traditional hardware, couple electronic circuitry on a flexible substrate to traditional circuitry, etc. Existing connector technologies including, for example, zero insertion force (ZIF) sockets may be problematic when used in conjunction with flexible substrates. For example, these types of connectors are attached to a substrate using certain connection points (e.g., via screwing, soldering, riveting, etc.). These connection points may form a strong attachment when a substrate is rigid. However, when used with a flexible substrate, the connection points may stress the pliable material to the point where a failure may occur in the functioning of the circuitry on the flexible substrate (e.g., due to extreme deformation of the flexible substrate.) 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference should be made to the following detailed description which should be read in conjunction with the following figures, wherein like numerals represent like parts: 
         FIG. 1  illustrates an example edge assembly for attaching to flexible substrates consistent with the present disclosure; 
         FIG. 2  illustrates example first edge component configurations along with an example flexible substrate consistent with the present disclosure; 
         FIG. 3  illustrates a side view of an example edge assembly consistent with the present disclosure; 
         FIG. 4  illustrates an example lighting device utilizing a flexible substrate and an edge assembly attached to the flexible substrate consistent with the present disclosure consistent with the present disclosure; 
         FIGS. 5A and 5B  illustrate an example port configured in a compression retainer component and an apparatus inserted into the example port consistent with the present disclosure; 
         FIG. 6  illustrates an example implementation of a lighting device consistent with the present disclosure; 
         FIG. 7  illustrates an example implementation of a socket capable of receiving an extension formed in the first edge component consistent with the present disclosure; and 
         FIG. 8  illustrates example operations for attaching an edge assembly to a flexible substrate consistent with the present disclosure. 
     
    
    
     Although the following Detailed Description will proceed with reference being made to illustrative embodiments, many alternatives, modifications and variations thereof will be apparent to those skilled in the art. 
     DETAILED DESCRIPTION 
     This disclosure is directed to an edge assembly for attaching to flexible substrates. In general, an assembly may couple to an edge of a flexible substrate to retain the substrate and, in at least one embodiment, may also electronically couple the flexible substrate to a power source. An example assembly may comprise at least a first edge component and a compression retainer component. An example first edge component may include at least one conductor to mate with conductors on a surface of a flexible substrate after the first edge component is affixed to an edge of the flexible substrate by the compression retainer component. The at least one conductor may convey power to at least one device (e.g., light emitting diode (LED)) mounted on the flexible substrate. The edge assembly may also comprise a second edge component, wherein the flexible substrate may be compressed between the first and second edge components and held in place by compressive force provided by the compression retainer component. The first/second edge components may be more rigid than the flexible substrate. The first edge component may further comprise an extension to which is routed an end of the at least one first edge component conductor. The extension may be accessible from outside of the edge assembly via a port in the compression retainer component. For example, the port may accept an apparatus (e.g., a power cable) for providing power to the flexible substrate via the extension. Alternatively, the port may allow the extension to be plugged into an external socket for delivering power to the flexible substrate. At least one benefit that may be realized by the edge assembly is that the flexible substrate may be held securely without being damaged while power is also conveyed to the flexible substrate. 
     In at least one embodiment, an assembly for coupling to a flexible substrate may comprise, for example, at least a first edge component and a compression retainer component. The first edge component may be to couple to a first surface of a flexible substrate. The first edge component may include at least one conductor to mate with at least one conductor on the first surface of the flexible substrate. The compression retainer component may affix at least the first edge component to the flexible substrate. 
     In at least one embodiment, the assembly may comprise a second edge component to couple to a second surface of the flexible substrate opposite of the first surface. The first edge component and the second edge component may be, for example, more rigid than the flexible substrate. The compression retainer component may then affix the first and second edge components to the flexible substrate by compressing the flexible substrate between the first and second edge components using a clipping action. The first surface may comprise at least one light emitting diode (LED) coupled to the at least one first surface conductor, the at least one first surface conductor causing the at least one LED to emit light by conveying power to the at least one LED. For example, the first surface may comprise a plurality of conductors and the first edge component may comprise a separate conductor to mate with each of the plurality of first surface conductors. Alternatively, the first surface may comprise a plurality of conductors and the first edge component comprises one conductor to mate with the plurality of first surface conductors concurrently. 
     In at least one embodiment, the first edge component may also comprise an extension to which an end of the at least one first edge component conductor is routed. The compression retainer component may comprise a port to accept the extension when the compression retainer component is affixing the first edge component to the flexible substrate. For example, the port may be configured to receive an apparatus to provide power to the flexible substrate via the extension. Alternatively, the assembly may further comprise a socket to receive the extension and to convey power to the flexible substrate via the extension. An example lighting device consistent with the present disclosure may comprise, for example, at least one flexible substrate, a power source and an assembly. The at least one flexible substrate may comprise at least one light emitting component. The assembly may retain at least an edge of the at least one flexible substrate to the cause the at least one light emitting component to emit light by conveying power from the power source to the at least one flexible substrate. The assembly may include, for example, at least a first edge component and a compression retainer component. The first edge component may couple to a first surface of the flexible substrate, the first edge component including at least one conductor to mate with at least one conductor on the first surface of the flexible substrate. The compression retainer component may affix at least the first edge component to the flexible substrate, the compressing retainer component including a port allowing power to be received from the power source. An example for affixing an assembly to a flexible substrate consistent with the present disclosure may comprise applying a first edge component including at least one conductor to a surface of a flexible substrate including at least one conductor in a manner that allows the at least one first edge component conductor to be coupled to the at least one flexible substrate conductor, and affixing the first edge component to the flexible substrate with a compression retention component. 
       FIG. 1  illustrates an example edge assembly for attaching to flexible substrates consistent with the present disclosure. Initially, it is important to note that while  FIG. 1  discloses an example configuration for system  100  comprising particular components arranged, coupled, oriented, etc. in a particular manner, the example configuration of  FIG. 1  is presented herein merely for the sake of explanation. Rearrangement, insertion, removal, replacement, etc. of the components in system  100  is permissible consistent with the teachings of the present disclosure. 
     System  100  may comprise flexible substrate  102  to which edge assembly  108  may be attached. Flexible substrate  102  may include at least conductors  104  and components  106 . For example, conductors  104  may be circuit traces based on a conductive material that is woven into flexible substrate  102 , embedded within flexible substrate  102 , bonded to flexible substrate  102 , sprayed/printed on flexible substrate  102  (e.g., using conductive ink), etc. For example, in at least one implementation conductors  104  may comprise copper strips or ribbons that are fully exposed (e.g., coupled to a surface of flexible substrate  102 ) or at least partially exposed (e.g., enclosed, at least in part, within flexible substrate  102 ) to a degree that allows selective coupling with other parts of system  100  such as other conductors, components, etc. Conductors  104  may also be extended beyond the edges of flexible substrate  102  to better facilitate external coupling. Components  106  may then be coupled to conductors  104  via solder, adhesive, a mechanical binding, etc. in manner that may allow power to be conveyed to components  106  via conductors  104 . The arrangement of conductors  104  and/or components  106  disclosed in  FIG. 1  is merely an example useful to explain various embodiments consistent with the present disclosure, and may vary depending on the particular application to which the teachings described herein may be applied. For example, the implementation disclosed in  FIG. 1  may be suitable for LED-based lighting. Components  106  may be LEDs arranged at certain locations along conductors  104  that may operate individually or in unison to generate a desired light output (e.g., from a fixture into which one or more flexible substrates  102  are embedded). 
     Edge assembly  108  may comprise, for example, at least first edge component  110  and compression retention component  118 . In at least one embodiment, edge assembly  108  may also include second edge component  116 . First edge component  110  and/or second edge component  116  may be constructed using a material that is more rigid that flexible substrate  102  such as, for example, traditional circuit board material, plastic, metal, etc. The use of a more rigid material may allow edge assembly  108  to both retain and protect the edge of flexible substrate  102 . First edge component  110  may comprise at least one conductor  112 . Conductor  112  is shown in  FIG. 1  as a plurality of individual conductors. Dotted lines have been used to indicate that conductor  112  is exposed on the non-visible (bottom) side of first edge component  110  (e.g., the side that will make contact with the surface of flexible substrate  102 ). The number of conductors  112  in first edge connector  110  may vary depending on how power is to be provided to conductors  104  in flexible substrate  102 . Different power schemes will be discussed in regard to  FIG. 2 . First edge component  110  may further comprise extension  114  to which ends of conductors  112  are routed. Extension  114  may constitute part of an interface through which power may be provided to flexible substrate  102 . Example interfaces will be described further in regard to  FIGS. 5 and 7 . 
     Compression retention component  118  may comprise, for example, at least extended members  120  and  122  that may generate compressive force to affix at least first edge component  110  to flexible substrate  102  using a “clipping” action (e.g., similar to how a binder clip may hold a group of papers together). Compression retention component  124  may be constructed of materials including, but not limited to, plastic, metal, wood, etc. such that extended members  120  and  122  may flex in manner allowing compression to be generated inwardly (e.g., towards each other). Compression retention component  118  may also comprise port  124  to accept extension  114  upon introduction of compression retention component  118  into edge assembly  108 . Port  124  may simply be a hole formed in the back of compression retention component  118  to allow external access to extension  114 . However, port  124  may further comprise mechanical retention and/or electrical components to accept an apparatus (e.g., a power cable) for conveying power to flexible substrate  102 . Different configurations for port  124  will be discussed in regard to at least  FIGS. 5 and 7 . In an example of operation employing both first edge connector  110  and second edge connector  116 , the edge of flexible substrate  102  may be positioned between first edge connector  110  and second edge connector  116 , as shown by the arrows labeled “A” and “B” in  FIG. 1 , so that conductors  112  in first edge component  110  are mated to conductors  104  as illustrated by the arrow labeled “C” in  FIG. 1 . Compression retention component  118  may then be applied to the combined first edge component  110 , flexible substrate  102  and second edge component  116 , as shown by the arrow labeled “D” in  FIG. 1 , so that extended members  120  and  122  compress flexible substrate  102  between first edge component  110  and second edge component  116 . During the application of compression retention component  118 , extension  114  may be received into port  124  so that extension  114  may be readily accessible from outside edge assembly  108  (e.g., so that a power source may be provide power to flexible substrate  102  via extension  114 ). While only one edge assembly  108  is shown in  FIG. 1 , edge assemblies may be attached to any or all of the edges of flexible substrate  102 . These further edge assemblies may or may not comprise any electronics (e.g., conductors  112 ) as they may serve a strictly structural purpose (e.g., to allow flexible substrate  102  to be formed into a certain shape or positioned in a particular orientation, to provide protection for the edges of flexible substrate  102 , etc.). 
       FIG. 2  illustrates example first edge component configurations along with an example flexible substrate consistent with the present disclosure.  FIG. 2  discloses an example system  100 ′ comprising at least flexible substrate  102 , edge assembly  108  and other edge assembly  200 . As discussed above, other edge assembly  200  may comprise electronics (e.g., to link system  100 ′ to another system) or may simply be a structural add-on to provide support to flexible substrate  102 . Along with system  100 ′, two example first edge components  110 (A) and  110 (B) are also illustrated. Similar to  FIG. 1 , first edge component  110 (A) comprises a plurality of conductors  112 (A), wherein each conductor  112 (A) corresponds to a conductor  104  in flexible substrate  102 . The configuration of conductors  112 (A) may allow for a controlled application of power to components  106  on a conductor-by-conductor basis. Given the example wherein system  100 ′ is being employed in a lighting device, performing conductor-by-conductor power control may allow for the generation of different intensities of light, different colors of light, etc. depending on how the LEDs on each conductor  104  are controlled. Alternatively, first edge component  110 (B) may comprise a single conductor  112 (B). Conductor  112 (B) may provide power to all of conductors  104  concurrently, and thus, all components  106  may operate in a similar manner. Again referring to the lighting example, the configuration of first edge connector  110 (B) may provide a way to generate substantially uniform light output from all LEDs, which may provide less control but may result in system  100 ′ being much simpler to implement, cost effective, etc. Further to the examples disclosed in  FIGS. 1 and 2 , other configurations are possible consistent with the present disclosure. For example, a plurality of conductors  112  having a total number less than the number of conductors  104  may be possible. Conductors  104  may then be “grouped” so that each conductor  112  services a group of conductors  104 . For example, two (2) conductors  112  may service all of conductors  104  with conductors  104  being divided into two groups on an alternating basis (e.g., every other conductor  104  is in the same group). This may allow for some flexibility in control without the level of complexity in a conductor-by-conductor solution. 
       FIG. 3  illustrates a side view of an example edge assembly consistent with the present disclosure.  FIG. 3  discloses edge assembly  108 ′ coupled to flexible substrate  102  comprising at least conductors  104 . Flexible substrate  102  may be sandwiched between first edge component  110  and second edge component  116 . While not visible in  FIG. 3 , at least one conductor  112  may mate with conductors  104  within the area where first edge component  110  comes into contact with the surface of flexible substrate  102 . The other end of conductor  112  may reside on extension  114  (e.g., to allow power to be provided to flexible substrate  102  via extension  114 ). Flexible substrate  102  may be retained between first edge component  110  and second edge component  116  by compression retention component  118 , which may comprise port  124  to provide a way for extension  114  to be accessed from outside of edge assembly  108 ′. 
       FIG. 4  illustrates an example lighting device utilizing a flexible substrate and an edge assembly attached to the flexible substrate consistent with the present disclosure. Lighting device  400  may comprise, for example, at least equipment  402  to which may be mounted at least power source  404 . Power source  404  may include circuitry to generate power from an internal source (e.g., a battery) or an external source (e.g., a power grid, a generator, etc.), and may further employ an apparatus  406  (e.g., a connector) to couple to edge assembly  108  for delivering power to flexible substrate  102 . The example disclosed in  FIG. 4  shows a lighting application, however embodiments consistent with the present disclosure are not specifically limited to only this usage. Any system that needs to power components  106  mounted on flexible substrate  102  may employ the various teachings that are described herein. 
     In lighting device  400 , flexible substrate  102  may be coupled to, and supported by, equipment  402  for the purpose of generating light. For example, flexible substrate  102  may be held or draped in a certain orientation so that light is emitted in a certain direction, with a certain intensity, etc. In one example implementation, lighting device  400  may be a ceiling mounted light fixture. Power supply  404  may generate power that may be provided to flexible substrate  102  via apparatus  406 . Apparatus  406  may plug into edge assembly  108 , which may convey the power to flexible substrate  102 . As discussed in regard to  FIGS. 1 and 2 , the power may be conveyed via extension  114  to flexible substrate  102 . The number of conductors  112  in first edge component  110  may dictate the amount of control over light output intensity, color, etc. 
       FIGS. 5A and 5B  illustrate an example port configured in a compression retainer component and an apparatus inserted into the example port consistent with the present disclosure. As shown in  FIG. 5A , apparatus  406  (e.g., a power cable connector) may insert into port  124  to, for example, convey power to flexible substrate  102 . As shown in  FIG. 5B , port  124  may enclose extension  114  in a manner that will guide an inserted apparatus  406  into a certain orientation allowing contact between a portion of apparatus  406  and extension  114 . In at least one embodiment, the certain orientation may allow conductors exposed on the portion of apparatus  406  that comes into contact with extension  114  to mate with the ends of conductors  112  (e.g., dark bands) situated on extension  114 . In this manner, the amount of power delivered to each conductor  112  may be controlled (e.g., given that first edge component  110  comprises a plurality of conductors  112 ). While not depicted in  FIG. 5 , consistent with the present disclosure first edge assembly  110  may comprise conductors  112  on both sides. As a result, extension  114  may have ends of conductors  112  on both sides, and apparatus  406  may be altered to mate with the ends of conductors  112  exposed on both sides of extension  114 . This configuration may be useful in a variety of implementations including, but not limited to, powering a single flexible substrate  102  wherein conductors  104  are coupled to both the top-side and bottom-side conductors  112  in edge assembly  108  (e.g., in a series circuit configuration), for powering two different flexible substrates  102  (e.g., back-to-back.) It is important to note that while a specific example of apparatus  406  coupling with port  124  has been illustrated in  FIG. 5 , that alternative configurations are possible consistent with the present disclosure. At least one alternative configuration is presented in  FIG. 7 . It may also be possible for a plurality of ports  124  to be formed into compression retention component  118  so that more than one apparatus  406  may be coupled to the same edge assembly  108 . In addition to receiving power for flexible substrate  102 , such a configuration may allow for implementations wherein, for example, more than one system  100  may be coupled together to support larger applications. 
       FIG. 6  illustrates an example implementation of a lighting device consistent with the present disclosure. Example lighting device  400 ′ comprises two systems  100 (A) and  100 (B) (e.g., flexible substrates  102  including edge assemblies  108 ) mounted within housing  600 . In the example implementation of systems  100 (A) and (B), flexible substrate  102  may be constructed by laminating conductors  104  between two sheets of PET. Openings may be formed in at least one of the two PET sheets to facilitate coupling components  106  (e.g., LEDs) to conductors  104 . In this manner, conductors may avoid contact with other conductive components (e.g., from becoming grounded by contacting housing  600 ), may be protected from damage, corrosion, etc. As mentioned previously, this example depicts at  602  and  604  how each system  100 (A) and (B) may include more than one edge assembly  108 . Including more than one edge assembly  108  in systems  100 (A) and (B) may allow for functionality in lighting device  400 ′ including, but not limited to, the ability to use various components  106  for supporting different types of lighting applications, the ability to couple lighting devices  400 ′ together for larger applications, etc. 
       FIG. 7  illustrates an example implementation of a socket capable of receiving an extension formed in the first edge component consistent with the present disclosure. Photograph  700  depicts a socket or connector  702  into which extension  114  may be inserted. For example, Socket  702  may comprise at least one conductor  704  that may mate with the end of at least one conductor  112  exposed on extension  114 . In at least one example implementation, socket  702  may be mounted in housing  600  as depicted in  FIG. 6 . Socket  702 , or more specifically the at least one conductor  704  in socket  702 , may then be coupled to, for example, a power source or to another system  100  in a chain configuration. 
       FIG. 8  illustrates example operations for attaching an edge assembly to a flexible substrate consistent with the present disclosure. In operation  800 , first edge component  110  may be applied to an edge of flexible substrate  102 . For example, first edge component  110  may be applied to flexible substrate  102  so that at least one conductor  112  in first edge component  110  may mate with conductors  104  in flexible substrate  102 . Operation  802  may be optional based on whether second edge component  116  is being utilized in edge assembly  108 . In operation  802 , second edge component  116  may be applied to flexible substrate  102  on a surface that is opposite of the surface to which first edge component  110  was applied in operation  800 . Compression retainer component  118  may then be applied over first edge component  110  and second edge component  116  in operation  804  so that flexible substrate  102  may be retained between the edge components. Operation  806  may be optional in that there may be no need to configure interface  114  in compression retainer component  118  (e.g., if port  124  is simply an opening formed in compression retainer component  118 ). However, given a situation wherein port  124  is a more complex construct (e.g., a socket to receive apparatus  406 , a connector, etc.), then in operation  806  some configuration may be required. Operation  808  may also be optional depending on what level of manufacture is being performed. For example, in operation  808  the edge assembly may be coupled to a power source. However, this coupling may be necessary only in certain situations (e.g., wherein system  100  is being installed into a lighting device  400 ). 
     While  FIG. 8  illustrates various operations according to an embodiment, it is to be understood that not all of the operations depicted in  FIG. 8  are necessary for other embodiments. Indeed, it is fully contemplated herein that in other embodiments of the present disclosure, the operations depicted in  FIG. 8 , and/or other operations described herein, may be combined in a manner not specifically shown in any of the drawings, but still fully consistent with the present disclosure. Thus, claims directed to features and/or operations that are not exactly shown in one drawing are deemed within the scope and content of the present disclosure. 
     As used in this application and in the claims, a list of items joined by the term “and/or” can mean any combination of the listed items. For example, the phrase “A, B and/or C” can mean A; B; C; A and B; A and C; B and C; or A, B and C. As used in this application and in the claims, a list of items joined by the term “at least one of” can mean any combination of the listed terms. For example, the phrases “at least one of A, B or C” can mean A; B; C; A and B; A and C; B and C; or A, B and C. 
     The term “coupled” as used herein refers to any connection, coupling, link or the like by which signals carried by one system element are imparted to the “coupled” element. Such “coupled” devices, or signals and devices, are not necessarily directly connected to one another and may be separated by intermediate components or devices that may manipulate or modify such signals. Likewise, the terms “connected” or “coupled” as used herein in regard to mechanical or physical connections or couplings is a relative term and does not require a direct physical connection. 
     Thus, this disclosure is directed to an edge assembly for attaching to flexible substrates. An example assembly may comprise at least a first edge component and a compression retainer component. An example first edge component may include at least one conductor to mate with conductors on a surface of a flexible substrate after the first edge component is affixed to an edge of the flexible substrate by the compression retainer component. The edge assembly may also comprise a second edge component, wherein the flexible substrate may be compressed between the first and second edge components and held in place by the compression retainer component. The first edge component may further comprise an extension, including the at least one conductor, that may be used to convey power from a power source to the flexible substrate. The extension is accessible from outside the flexible substrate via a port in the compression retainer component. 
     According to one aspect there is provided an assembly for coupling to a flexible substrate. The assembly may comprise a first edge component to couple to a first surface of a flexible substrate, the first edge component including at least one conductor to mate with at least one conductor on the first surface of the flexible substrate and a compression retainer component to affix at least the first edge component to the flexible substrate. 
     According to another aspect there is provided a lighting device. The lighting device may comprise at least one flexible substrate comprising at least one light emitting component, a power source and an assembly to retain at least an edge of the at least one flexible substrate and to the cause the at least one light emitting component to emit light by conveying power from the power source to the at least one flexible substrate, the assembly including a first edge component to couple to a first surface of the flexible substrate, the first edge component including at least one conductor to mate with at least one conductor on the first surface of the flexible substrate and a compression retainer component to affix at least the first edge component to the flexible substrate, the compressing retainer component including a port allowing power to be received from the power source. 
     According to another aspect there is provided a method for affixing an assembly to a flexible substrate. The method may comprise applying a first edge component including at least one conductor to a surface of a flexible substrate including at least one conductor in a manner that allows the at least one first edge component conductor to be coupled to the at least one flexible substrate conductor and affixing the first edge component to the flexible substrate with a compression retention component. 
     While the principles of the invention have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the invention. Other embodiments are contemplated within the scope of the present invention in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the following claims.