PATENT DOCUMENT

Publication Number: US-8797748-B2
Application Number: US-201113316348-A
Country: US
Kind Code: B2

Title: Electronic devices with tubular flexible circuitry

Abstract:
An electronic device may be provided that has flexible circuitry such as spiral wrapped flexible circuitry. Flexible circuitry may be connected to one or more sides of an electronic component such as rigid printed circuit board or coupled between a rigid printed circuit board an another device component. Flexible circuitry may include an adhesive strip for maintaining a spiral wrap configuration of the flexible circuitry. An adhesive strip may be covered by a removable protective liner during manufacturing of an electronic device so that the flexible circuitry may be tested in a flat, unrolled configuration prior to installation in the electronic device. Flexible circuitry may include a conductive layer configured to form an electromagnetic shield for an electronic component mounted in the spiral wrap. Flexible circuitry may be wrapped around an elongated support member that is mounted along an edge of the electronic component.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 a printed circuit board; 
 an elongated support member mounted along an edge of the printed circuit board; and 
 flexible circuitry that is wrapped around the elongated support member and electrically coupled to the printed circuit board, wherein the flexible circuitry comprises a flexible printed circuit, wherein the flexible printed circuit comprises a first connector attached to a first portion of the printed circuit board and a second connector attached to a second portion of the printed circuit board, and wherein the second portion of the printed circuit board is displaced from the first portion of the printed circuit board along a lateral dimension of the printed circuit board that is parallel to an elongated dimension of the elongated support member. 
 
     
     
       2. The electronic device defined in  claim 1 , further comprising a housing, wherein the elongated support member comprises an engagement member attached to the housing. 
     
     
       3. The electronic device defined in  claim 1  wherein the elongated support member comprises an engagement member attached to the printed circuit board. 
     
     
       4. The electronic device defined in  claim 1 , further comprising an electronic component, wherein the elongated support member includes at least one planar surface, wherein a portion of the flexible printed circuit is wrapped adjacent to the at least one planar surface, and wherein the electronic component is mounted to the portion of the flexible printed circuit. 
     
     
       5. The electronic device defined in  claim 4  wherein the portion of the flexible printed circuit further comprises an internal rigid member that locally stiffens the flexible printed circuit for mounting the electronic component. 
     
     
       6. The electronic device defined in  claim 1  wherein the flexible printed circuit further comprises a conductive ground layer. 
     
     
       7. The electronic device defined in  claim 6 , further comprising an electronic component, wherein the conductive ground layer is configured to form an electromagnetic shield for the electronic component. 
     
     
       8. An electronic device, comprising:
 a printed circuit board; 
 an elongated support member mounted along an edge of the printed circuit board; 
 flexible circuitry that is wrapped around the elongated support member and electrically coupled to the printed circuit board, wherein the flexible circuitry comprises a flexible printed circuit; 
 an electronic component, wherein the flexible printed circuit comprises a first connector attached to the printed circuit board and a second connector attached to the electronic component; and 
 a housing having a lower portion and an upper portion that is configured to pivot with respect to the lower portion, wherein the printed circuit board is mounted in the lower portion and wherein the electronic component is mounted in the upper portion. 
 
     
     
       9. A electronic device, comprising:
 a printed circuit board; and 
 a flexible printed circuit having an adhesive strip and first and second connectors, wherein the first connector is attached to a first portion of the printed circuit board and the second connector is attached to a second portion of the printed circuit board, wherein the second portion is displaced from the first portion along a lateral dimension of the printed circuit board, wherein the flexible printed circuit is formed in a spiral wrap that extends along the lateral dimension of the printed circuit board, and wherein the adhesive strip is configured to prevent unwrapping of the spiral wrap. 
 
     
     
       10. The electronic device defined in  claim 9  wherein the first and second portions of the printed circuit board each comprise a portion of a common surface of the printed circuit board. 
     
     
       11. The electronic device defined in  claim 9  wherein the first portion of the printed circuit board comprises a portion of a first surface of the printed circuit board and wherein the second portion of the printed circuit board comprises a portion of an opposing second surface of the printed circuit board. 
     
     
       12. The electronic device defined in  claim 9  wherein the flexible printed circuit comprises a first surface having an edge and an opposing second surface, wherein the adhesive strip is formed along the edge of the first surface, and wherein the adhesive strip attaches the edge of the first surface to the opposing second surface. 
     
     
       13. The electronic device defined in  claim 9 , further comprising a support member that extends along the lateral dimension of the printed circuit board, wherein the flexible printed circuit comprises a surface having an edge, wherein the adhesive strip is formed along the edge, wherein the spiral wrap runs around the support member, and wherein the adhesive strip attaches the edge to the support member. 
     
     
       14. An electronic device, comprising: a tubular flexible printed circuit; and circuitry coupled to the tubular flexible printed circuit, wherein the tubular flexible printed circuit comprises a spirally wrapped flexible printed circuit and wherein the spirally wrapped flexible printed circuit has a first end coupled to the printed circuit board at a first location and has a second end coupled to the printed circuit board at a second location. 
     
     
       15. The electronic device defined in  claim 14  wherein the circuitry that is coupled to the tubular flexible printed circuit comprises at least one integrated circuit mounted to the printed circuit board.

Description:
BACKGROUND 
     This relates generally to electronic devices, and more particularly, to electronic devices with flexible circuitry. 
     Electronic devices such as portable computers and cellular telephones are often provided with rigid components and flexible circuits. For example, a flexible printed circuit is often used to connect a rigid printed circuit board to other device components or to route electrical signals from one portion of a rigid printed circuit board to another portion of a rigid printed circuit board. 
     Flexible printed circuits are often mounted in a stack of components, thereby increasing the total thickness of the component stack. While flexible circuits are typically thin (less than 3 mm) even the additional thickness of a flex circuit in a component stack can be problematic in a compact electronic device. 
     It would therefore be desirable to be able to provide improved electronic devices. 
     SUMMARY 
     An electronic device may be provided that has tubular flexible circuitry. 
     Tubular flexible circuitry may be formed from a tubular flexible circuit printed circuit, a tubular flexible ribbon cable or other tubular flexible circuitry. 
     Tubular flexible circuitry may be formed from a tubular flexible substrate having an elongated opening, or may be formed from elongated flexible circuitry that is rolled or wrapped to form a tubular flexible circuitry. Wrapped flexible circuitry may be formed from a spirally wrapped flexible printed circuit, a spirally wrapped flexible ribbon cable, etc. 
     An electronic device may include additional circuitry such as integrated circuits coupled to the tubular flexible circuitry. Circuitry such as integrated circuits may be mounted to a printed circuit board. Tubular flexible circuitry may be connected to one or more locations on the printed circuit board. 
     For example, tubular circuitry may include a first end coupled to a first location on a printed circuit board and a second end coupled to a common or opposing side of the printed circuit. If desired, tubular flexible circuitry may include a first end coupled to a first location on a printed circuit board and a second end coupled to another device component such as a display, an additional printed circuit board, etc. 
     Flexible circuitry may include an adhesive strip for maintaining a wrapped tubular configuration of the flexible circuitry such as a spiral wrapped (or spirally wrapped) configuration. An adhesive strip may be covered by a removable protective liner during manufacturing of an electronic device so that the flexible circuitry may be tested in a planar configuration prior to installation in the electronic device. 
     Flexible circuitry may have multiple flexible layers. Flexible layers of flexible circuitry may include a conductive layer such as a conductive ground layer configured to form a conductive shield for an internal electronic component that is surrounded by, for example, a spiral wrapped flexible printed circuit. 
     Flexible circuitry may be mounted to a rigid support structure such as an elongated support member. An elongated support member may be formed from active or inactive components of the device. Elongated support members may be mounted to device housing structures, printed circuit boards or other device structures or components using screws or other fasteners, clips, protrusions and mating recesses, grooves, and other engagement features, glue, welds, or other suitable attachment mechanisms. 
     Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device such as a laptop computer with a display in accordance with an embodiment of the present invention. 
         FIG. 2  is a perspective view of an illustrative electronic device such as a handheld electronic device with a display in accordance with an embodiment of the present invention. 
         FIG. 3  is a perspective view of an illustrative electronic device such as a tablet computer with a display in accordance with an embodiment of the present invention. 
         FIG. 4  is a cross-sectional side view of a portion of an illustrative electronic device having flexible circuitry that runs around a rigid support member in accordance with an embodiment of the present invention. 
         FIG. 5  is a perspective view of illustrative flexible circuitry connected to multiple contacts on a rigid printed circuit in accordance with an embodiment of the present invention. 
         FIG. 6  is a perspective view of illustrative flexible circuitry connected to multiple contacts on opposing sides of a rigid printed circuit in accordance with an embodiment of the present invention. 
         FIG. 7  is a perspective view of illustrative flexible circuitry connected to multiple internal electronic components of an electronic device in accordance with an embodiment of the present invention. 
         FIG. 8  is a perspective view of illustrative flexible circuitry having an adhesive strip with a removable cover and connectors on opposing sides in accordance with an embodiment of the present invention. 
         FIG. 9  is a perspective view of illustrative flexible circuitry having an adhesive strip with a removable cover and multiple connectors on a common side in accordance with an embodiment of the present invention. 
         FIG. 10  is a cross-sectional side view of illustrative flexible circuitry having an adhesive strip with a removable cover in accordance with an embodiment of the present invention. 
         FIG. 11  is a perspective view of a portion of illustrative flexible circuitry mounted to a rigid support structure in accordance with an embodiment of the present invention. 
         FIG. 12  is a perspective view of a portion of illustrative flexible circuitry wrapped around a rigid support structure having planar surfaces in accordance with an embodiment of the present invention. 
         FIG. 13  is a cross-sectional side view of illustrative flexible circuitry having a conductive ground layer in accordance with an embodiment of the present invention. 
         FIG. 14  is a cross-sectional side view of illustrative flexible circuitry of the type shown in  FIG. 13  showing how a ground layer in wrapped flexible circuitry may form a conductive shield in accordance with an embodiment of the present invention. 
         FIG. 15  is a diagram of an illustrative test system for programming and testing flexible circuitry in accordance with an embodiment of the present invention. 
         FIG. 16  is a flow chart of illustrative steps involved in testing and installing flexible circuitry for an electronic device in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic devices may include tubular flexible circuitry. Tubular flexible circuitry may include a flexible printed circuit of flexible ribbon cable. Tubular flexible circuitry may be formed from a spiral roll of flexible circuitry in an extended internal volume of an electronic device. Mounting tubular flexible circuitry in an extended internal volume may help reduce the thickness of component stacks in the electronic device thereby helping reduce the overall thickness of the device. Tubular flexible circuitry may be used to electrically connect multiple rigid components in the electronic device or to transmit electrical signals from one portion of an electronic component such as a printed circuit board to another portion of the electronic component. 
     Illustrative electronic devices that may be provided with tubular flexible circuitry are shown in  FIGS. 1 ,  2 , and  3 .  FIG. 1  shows how electronic device  10  may have the shape of a laptop computer having upper housing  12 A and lower housing  12 B with components such as keyboard  16  and touchpad  18 . Tubular flexible printed circuits may be used to couple circuitry such as electronic components mounted in upper housing  12 A to circuitry such as electronic components mounted in lower housing  12 B. Portions of a tubular flexible printed circuit may extend from a portable computer clutch barrel such as clutch barrel  13  into upper and lower housing portions  12 A and  12 B for connection to electrical components of device  10 . 
       FIG. 2  shows how electronic device  10  may be a handheld device such as a cellular telephone, music player, gaming device, navigation unit, or other compact device.  FIG. 3  shows how electronic device  10  may be a tablet computer. These are merely illustrative examples. Electronic devices such as illustrative electronic device  10  of  FIGS. 1 ,  2 , and  3  may be laptop computers, computer monitors with embedded computers, tablet computers, cellular telephones, media players, other handheld and portable electronic devices, smaller devices such as wrist-watch devices, pendant devices, headphone and earpiece devices, other wearable and miniature devices, or other electronic equipment. 
     Device  10  may have one or more housing structures such as housing  12 . Housing  12 , which is sometimes referred to as a case, may be formed of materials such as plastic, glass, ceramics, carbon-fiber composites and other composites, metal, other materials, or a combination of these materials. Device  10  may be formed using a unibody construction in which most or all of housing  12  is formed from a single structural element (e.g., a piece of machined metal or a piece of molded plastic) or may be formed from multiple housing structures (e.g., outer housing structures that have been mounted to internal frame elements or other internal housing structures). 
     Device  10  may have one or more displays such as display  14 . Display  14  may be an organic light-emitting diode (OLED) display or other suitable display. Display  14  may include display pixels formed from light-emitting diodes (LEDs), organic LEDs (OLEDs), plasma cells, electronic ink elements, liquid crystal display (LCD) components, or other suitable display pixel structures compatible with flexible displays. Display  14  may, if desired, include capacitive touch sensor electrodes for a capacitive touch sensor array or other touch sensor structures (i.e., display  14  may be a touch screen). Touch sensor electrodes may be provided on a touch panel layer that is interposed between an organic light-emitting diode display layer and a transparent cover layer (e.g., a cover glass layer), may be formed on the underside of a cover layer, or may otherwise be incorporated into display  14 . 
     The display (sometimes referred to as the display layer, the OLED display, the flexible display or flexible OLED display) may have a planar rectangular active region in its center. The rectangular active region may include an array of light-emitting diode pixels. Display  14  may include an inactive portion at the edges of display  14 . The inactive portion of the display is shown as inactive border region  20  in  FIGS. 1 ,  2 , and  3 . 
     To enhance device aesthetics, the thickness of electronic device  10  may be reduced by coupling electronic components together in device  10  using tubular flexible circuitry such as a tubular flexible printed circuit mounted in an extended internal volume adjacent to the electronic components. 
     A cross-sectional side view of a portion of an illustrative electronic device having tubular flexible circuitry is shown in  FIG. 4 . As shown in  FIG. 4 , device  10  may include one or more components such as components  30  and components  32  mounted in a housing such as housing  12 . In the example of  FIG. 4 , housing  12  and a display such as display  14  form an enclosure in which components  30  and  32  are mounted. However, this is merely illustrative. Components  30  and  32  may be fully enclosed by housing  12 , may be fully enclosed by display  14  or may be otherwise mounted in device  10 . 
     Components such as component  32  may be active or inactive components of device  10 . Components  30  may include rigid support structures or may include a device component such as a battery, printed circuit board (PCB) or other active component or electrical component (e.g., a capacitor, a resistor, a speaker, a vibrator, an actuator, etc.). Component  32  may be mounted to device housing  12 , to component  30 , to display  14  or otherwise mounted in device  10 . Component  32  may, for example, be an integrated circuit mounted to component  30 . Component  32  may be a separate electronic component mounted to component  30  using a layer of adhesive interposed between component  30  and component  32 . Components  30  and  32  may, for example, be mounted to device housing structures such as housing  12  using screws or other fasteners, clips, protrusions and mating recesses, grooves, and other engagement features, glue, welds, or other suitable attachment mechanisms. 
     Component  30  may be an electronic component such as a printed circuit, a printed circuit board, an integrated circuit, or other electronic component. Printed circuit  30  and other printed circuits in device  10  may be formed from rigid printed circuit board material (e.g., fiberglass-filled epoxy), flexible sheets of material such as polymers, or a combination of rigid and flexible materials (sometimes referred to as “rigid-flex” printed circuit boards). 
     As shown in  FIG. 4 , device  10  may be provided with tubular flexible circuitry such as flexible circuitry  34 . Flexible circuitry  34  may include a flexible printed circuit, a flexible ribbon cable or other flexible circuitry. Flexible printed circuits (“flex circuits”) such as flexible circuitry  34  may, for example, be formed using printed conductive traces on flexible sheets of polyimide. Tubular flexible circuitry  34  may be connected to a portion of a printed circuit board such as printed circuit  30 . Flexible circuitry  34  may have a tubular portion that is wrapped around a support member such as support member  38 . Support member  38  may be an inactive or active component of device  10 . For example, support member  38  may include an inactive support structure formed from a material such as plastic, metal, a fiber-composite material, ceramic, other materials, or combinations of these materials. If desired, support member  38  may include an active component such as a cylindrical battery cell. 
     Support member  38  may have a curved outer surface. For example, support member  38  may be characterized by a minimum bend radius R. The size of bend radius R may be selected to prevent damage to flexible circuitry  34 . For example, the size of R may be 1 mm, 2 mm, less than 3 mm, less than 2 mm, less than 1 mm, or less than 0.5 mm (as examples). 
     Flexible circuitry  34  may be have a tubular portion such as portion  34 W that is wrapped around support member  38  in, for example, a spiral wrap that extends along a dimension parallel to the y-axis of  FIG. 4 . Flexible circuitry  34  may have one or more portions such as portion  34 C that extend from support member  38  in the direction of printed circuit  30  and that are electrically coupled to printed circuit  30 . However, this is merely illustrative. If desired, support member  38  may be a temporary support member for inserting rolled printed circuit  34  into device  10  during manufacturing of device  10 . If desired, support member  38  may be removed from wrapped portion  34 W of flexible circuitry  34  prior to completion of manufacturing of device  10 . 
     Flexible circuitry  34  may have first and second ends that are provided with one or more connectors such as connector  35  for connecting flexible circuitry  34  to a printed circuit board or other component such as component  30 . Connector  35  may be formed from any suitable connection mechanism such as a Zero Insertion Force (ZIF) connector, a board-to-board connector, a 16-pin connector, a wired connection, a wire bond connection, etc. In the example of  FIG. 4 , connector  35  of flexible circuitry  34  is a conductive contact connected to a contact pad such as bond pad  36  on printed circuit  30 . Connector  35  of flexible circuitry  34  may be connected to bond pad  36  using, for example, anisotropic conductive film (ACF). Bond pad  36  may be connected to one or more conductive traces in printed circuit  30 . 
     As shown in  FIG. 4 , device  10  may be provided with additional electronic components such as component  40  that are at least partially surrounded by wrapped portion  34 W (sometimes called tubular portion  34 W) of flexible circuitry  34 . Component  40  may be an integrated circuit, a speaker, a light-emitting diode (LED), a vibrator, an actuator, or other electronic component. If desired, flexible circuitry  34  may include a conductive ground layer that, in the wrapped configuration of  FIG. 4 , provides electrical shielding for components such as component  40 . 
     Flexible circuitry  34  may have an end such as portion  34 C having a connector such as connector  35  connected to printed circuit  30  and an opposing end  34 C having an additional connector  35  that makes an electrical connection elsewhere in device  10  (e.g., to another portion of printed circuit  30 , to another electronic component such as component  32 , to another printed circuit board, to display  14 , etc.). 
     As shown in  FIG. 5 , tubular flexible circuitry  34  may be formed from a spirally wrapped flexible printed circuit. In the example of  FIG. 5 , spiral wrapped flexible circuitry  34  is configured to carry electrical signals between multiple contacts on a common side of printed circuit  30 . Flexible circuitry  34  may be wrapped or rolled around support member  38  such that a connector such as connector  35  on first portion  34 C is connected to a bond pad  36  on a first portion of a printed circuit board such as component  30  and a second connector  35  on a second portion  34 C is connected to a second bond pad  36  on a different portion of component  30 . Flexible circuitry  34  may be wrapped around support member  38  in a spiral wrap that extends along a lateral dimension of component  30  parallel to the y-axis of  FIG. 5 . 
     A spiral wrapped flexible printed circuit such as flexible circuitry  34  may have seams such as seams  44 . Seams  44  may be partially overlapping seams (e.g., one portion of flexible circuitry  34  may overlap another portion of flexible circuitry  34 ) or seams  44  may be formed from abutting edges of flexible circuitry  34 . 
     This is merely illustrative. If desired, flexible circuitry  34  may be formed from a single tubular flexible substrate having an opening in which support member  38  may be inserted. 
     If desired, flexible printed circuit may include a conductive ground layer such as layer  48 . Flexible circuitry  34  may include conductive contacts such as contact  46  that electrically couple layer  48  across seams  44  so that layer  48  forms a continuous conductive shield at least partially surrounding support member  38  or another component mounted within a space created by wrapped portion  34 W of circuit  34 . 
     In the example of  FIG. 5 , tubular flexible circuitry  34  is coupled to bond pads  36  on a common surface of component  30 . However, this is merely illustrative. If desired, tubular flexible circuitry  34  may be configured to connect to bond pads (or other connectors) on opposing sides of a component such as component  30  as shown in  FIG. 6 . In the example of  FIG. 6 , flexible circuitry  34  is configured to couple a contact pad such as bond pad  36  on top surface  50  of component  30  to a second contact pad  36  on an opposing bottom surface such as surface  52  of component  30 . In configurations in which flexible circuitry  34  is coupled to bond pads on opposing sides of a printed circuit board such as component  30 , flexible circuitry may be formed from a wrapped flexible printed circuit including conductive connectors  35  on opposing sides of flexible circuitry  34 . 
     As shown in  FIG. 7 , rolled flexible circuitry  34  may be configured to electrically connect a first component such as component  30  to a second component such as component  30 ′. Second component  30 ′ may be a printed circuit board, a display such as display  14 , control circuitry, an integrated circuit or other electronic component. If desired, components  30  and  30 ′ may be mounted in lower and upper portions of an electronic device  10  such as lower and upper housings  12 B and  12 A, respectively, of  FIG. 1 . 
     For example, component  30  may be a printed circuit board mounted in lower housing portion  12 B that is coupled to a component  30 ′ such as display  14  mounted in upper housing  12 A. If desired, component  30  may be configured to move with respect to component  30 ′ (e.g., using a hinge structure in housing  12  that allows upper and lower portions  12 A and  12 B to pivot as indicated by arrows  56 ). 
     For example, support member  38  and an associated flexible circuitry  34  that is wrapped around support member  38  may, for example, be mounted in a portable computer clutch barrel such as clutch barrel  13  (see  FIG. 1 ) containing hinges that allow the lid of the portable computer to open and close. Portions  34 C may extend from portable computer clutch barrel  13  into upper and lower housing portions  12 A and  12 B for connection to components such a components  30  and  30 ′. 
     In configurations in which component  30  is configured to move with respect to component  30 ′, flexible circuitry  34  may be loosely wrapped around support member  38  so that flexible circuitry  34  can couple to components  30  and  30 ′ without generating strain on connectors  35  that couple flexible circuitry  34  to components  30  and  30 ′. 
     As shown in  FIG. 7 , a first portion  34 C of flexible circuitry  34  may include a connector  35  that is coupled to a contact pad such as bond pad  36 ′ on a top surface  50 ′ of component  30 ′. Flexible circuitry  34  may include a connector  35  that is coupled to a contact pad such as bond pads  36  on a bottom surface  52  of component  30  (see, e.g.,  FIG. 6 ). However, this is merely illustrative. If desired, flexible circuitry  34  may be connected to top surface  50 ′, bottom surface  52 ′ or elsewhere on component  30 ′. If desired, flexible circuitry  34  may be connected to top surface  50 , bottom surface  52  or elsewhere on component  30 . 
     In configurations in which flexible circuitry  34  is coupled to bond pads on a common side of components such as components  30  and/or  30 ′, flexible circuitry may include conductive connectors  35  on opposing sides of flexible circuitry  34  as shown in  FIG. 8 . 
       FIG. 8  is a perspective view of flexible circuitry  34  showing how connectors  35  may be formed on extended portions  34 C. Flexible circuitry  34  may be configured to be able to be laid substantially flat (e.g., in a planar configuration in the x-y plane shown in  FIG. 8 ). Flexible circuitry  34  may be laid flat in a planar configuration for testing and configuration of flexible circuitry  34  during manufacturing of device  10 . 
     Flexible circuitry  34  may be configured to have a substantially planar portion  34 W (when laid flat) that is parallel to the x-y plane and extends along a lateral dimension parallel to the x-axis shown in  FIG. 8 . Flexible circuitry  34  that can be laid flat may allow testing of flexible circuitry  34  using simplified testing systems. Flexible circuitry may be configured to have end portions  34 C that form additional planar portions (when laid flat) in the x-y plane and extending along a lateral dimension between the x and y axes shown in  FIG. 8 . Conductive paths such as traces  64  may be formed within flexible circuitry  34  that electrically couple connectors  35  on opposing ends  34 C of flexible circuitry  34 . 
     Flexible circuitry  34  may include a strip of adhesive such as adhesive  60  that runs along an edge of portion  34 W. Adhesive  60  may be a pressure sensitive adhesive or other type of adhesive. Adhesive  60  may be provided with a removable protective liner such as layer  62  that covers adhesive  34  during shipping, testing, and manufacturing of flexible circuitry  34 . Protective layer  62  may be provided with an extended portion such as pull tab  66 . Pull tab  66  may help a technician remove layer  62  from adhesive  60  so that flexible circuitry  34  may be rolled or wrapped around a support member for installation into device  10 . 
     During manufacturing of device  10 , flexible circuitry  34  may be wrapped so that adhesive  60  on a first side of circuitry  34  (e.g., top side  50 ) bonds to an opposing side (e.g., bottom side  52 ) of portion  34 W at seams (see, e.g.,  FIG. 6 ). Adhesive  60  may be configured to help flexible circuitry  34  that has been rolled or wrapped for insertion into a device such as device  10  of  FIG. 1  maintain a rolled or spiral wrapped configuration. 
     The example of  FIG. 8  in which connectors  35  are formed on opposing sides of flexible circuitry  34  is merely illustrative. In configurations in which flexible circuitry  34  is coupled to bond pads on opposing sides of components such as components  30  and/or  30 ′, flexible circuitry may include conductive connectors  35  on a common side of flexible circuitry  34  as shown in  FIG. 9 . 
     As shown in  FIG. 9 , flexible circuitry  34  may include connectors  35  on a common side (e.g., top side  50 ) of extended portions  34 C. Flexible circuitry  34  having connectors  35  on a common side (e.g., top side  50 ) of extended portions  34 C may be laid flat in a planar configuration for testing and configuration of flexible circuitry  34  during manufacturing of device  10 . 
     Extended portions  34 C having connectors  35  on a common side may be configured to form planar portions (when laid flat) in the x-y plane and extending along a lateral dimension between the x and y axes shown in  FIG. 9 . 
     As shown in  FIG. 10 , adhesive  60  may be formed on a surface such as top surface  50  of flexible circuitry  34  along an edge of flexible circuitry  34 . Protective layer  62  may be configured to cover adhesive  60 . Extended portion  66  may extend from an edge of flexible circuitry  34  to aid in removing protective layer  62  from adhesive  34  during assembly of a device such a device  10 . 
     A support member such as support member  38  for wrapping flexible circuitry  34  may, if desired, include an engagement member such as engagement member  70  as shown in  FIG. 11 . Engagement member  70  may be used to mount support member  38  to other structures such as structure  71  of device  10 . Structure  71  may be a portion of, for example, housing  12 , component  30 , component  32 , or display  14  (see, e.g.,  FIG. 4 ) of device  10 . Engagement member  70  may include one or more hooks, screws or other fasteners, clips, protrusions or mating recesses, grooves, welded portions, or other suitable attachment mechanisms. 
     If desired, support member  38  may have one or more planar surfaces as shown in  FIG. 12 . As shown in  FIG. 12 , flexible circuitry  34  may be wrapped around support member  38  having planar surfaces  74 . Portions of flexible circuitry  34  that are wrapped adjacent to planar surfaces  74  of support member  38  may be provided with additional electronic components such as components  78  mounted to flexible circuitry  34 . Components  78  may include integrated circuits, discrete components such as resistors, capacitors, and inductors, and other electronic components. 
     Flexible circuitry  34  may include one or more internal rigid members such as stiffeners  76 . Components  78  may be mounted to flexible circuitry  34  over stiffeners  76 . Stiffeners  76  may be configured to locally stiffen flexible circuitry  34  to prevent bending of flexible circuitry  34  in the vicinity of a component such as components  78  in order to prevent damage or dislodging of components  78 . 
       FIG. 13  is a cross-sectional end view of portion  34 W of flexible circuitry  34  showing how flexible circuitry  34  may include a conductive ground layer such as ground layer  48 . Flexible circuitry  34  may be formed from one or more flexible substrate layers. Conductive lines such as traces  64  may be formed on a surface of one or more flexible substrate layers within or on flexible circuitry  34 . 
     As shown in  FIG. 13 , flexible circuitry  34  may include conductive contacts such as contacts  46  that electrically couple layer  48  to surfaces  50  and  52  of flexible circuitry  34 . Conductive vias such as vias  82  may be formed in flexible circuitry  34  to form a conductive bridge between layer  48  and contacts  46  on surfaces  50  and  52 . 
     Flexible circuitry  34  may be wrapped around a support member such as support member  38  so that contacts  46  on top surface  50  are mounted in contact with contacts  46  of opposing surface  52  at seams  44  as shown in  FIG. 14 . Conductive layer  48  may be coupled to contacts  46  at seams  44  so that layer  48  forms a continuous conductive shield. The continuous conductive shield formed by layer  48  and contacts  46  may at least partially surround support member  38  and/or another component such as component  40  mounted within a space created by wrapped portion  34 W of circuit  34 . Component  40  may be mounted within support member  38 , as an integrated portion of member  38 , or in a space created by wrapped portion  34 W that is separate from member  38 . 
     During manufacturing of device  10 , flexible circuitry  34  may be connected to a test system such as test system  90  as shown in  FIG. 15 . Test system  90  may include test equipment  92  and one or more test cables  94 . As shown in  FIG. 15 , test cables  94  may be connected to connectors  35  of flexible circuitry  34  during testing of flexible circuitry  34   
     Test equipment  92  may include computing equipment, monitoring equipment, programming equipment or other equipment for testing flexible circuitry  34  during manufacturing of device  10 . For example, test equipment  92  may be configured to perform tests on flexible circuitry  34  to verify that flexible circuitry  34  has been programmed properly and is functioning properly (viability verification tests). During testing of flexible circuitry  34 , test data may be conveyed between test equipment  92  and flexible circuitry  34 . 
       FIG. 16  is a flow chart of illustrative steps involved in manufacturing electronic device  10  of  FIG. 1 . 
     At step  100 , flexible circuitry such as flexible circuitry  34  may be connected to test equipment such as test equipment  92  of  FIG. 2  and testing and programming of flexible circuitry  34  may be performed. 
     At step  102 , flexible circuitry  34  may be disconnected from test equipment  92 . 
     At step  104 , if flexible circuitry  34  has successfully passed testing, a protective liner such as protective layer  62  may be removed from an adhesive strip such as adhesive strip  60  of  FIG. 8 . 
     At step  106 , flexible circuitry  34  may be wrapped around an elongated support member such as support member  38  of (for example)  FIG. 4 . Flexible circuitry  34  may be wrapped in a spiral wrap so that adhesive  60  on a first side of flexible circuitry  34  bonds to an opposing side of flexible circuitry  34  or to support member  38  forming seams  44 . If desired, flexible circuitry  34  may be wrapped in a spiral wrap so that contacts such as contacts  46  of  FIGS. 13 and 14  on a first side of flexible circuitry  34  form an electrical connection with contacts  46  on an opposing side of flexible circuitry  34  at seams  44 . 
     At step  108 , connectors  35  of flexible circuitry  34  that has been wrapped in a spiral wrap around a support member may be electrically connected to device components such as components  30 ,  30 ′ and  32 . If desired, the support member may be removed from the spiral wrap. However, this is merely illustrative. If desired, the support member may remain in the spiral wrap. 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention.

Metadata:
Filing Date: 20111209
Publication Date: 20140805
Grant Date: 20140805
Priority Date: 20111209
Inventors: DABOV TEODOR
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K1/0281", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/147", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/09027", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/2009", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49004", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/0281", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/051", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49117", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/028", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1613", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/051", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1613", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/056", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/2009", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/147", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/028", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/09027", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/056", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 48571815