PATENT DOCUMENT

Publication Number: US-9666967-B2
Application Number: US-201414444424-A
Country: US
Kind Code: B2

Title: Printed circuit board connector for non-planar configurations

Abstract:
A mesh network of printed circuit boards (PCBs) including a first PCB coupled to a second rigid PCB by way of an interlocking connection is provided. The interlocking connection has a degree of freedom that allows the first and second PCBs to form a twist angle between each other; the interlocking connector configured to provide electrical coupling between active components disposed in each of the first and second PCBs. A method of forming a substrate fabric including a mesh network as above is also provided. Further provided is a method of activating the mesh network of printed circuit boards as above.

Claims:
What is claimed is: 
     
       1. A mesh network of printed circuit boards (PCBs), comprising:
 a first rigid PCB defining a first securing mechanism; 
 a second rigid PCB defining a second securing mechanism; 
 wherein the first and second securing mechanisms join one another to form an interlocking connection between the first and second rigid PCBs; 
 the interlocking connection is configured to allow the first and second PCBs to form a first twist angle around a first axis that is transverse to the interlocking connection and a second twist angle around a second axis that is oriented at a non-zero angle with respect to the first axis, wherein the first twist angle is formed in response to a torsion applied about the first axis; and 
 the interlocking connection is configured to electrically couple the first and second PCBs. 
 
     
     
       2. The mesh network of  claim 1  wherein:
 the first securing mechanism comprises a pin connector in the first PCB having a plurality of pins; and 
 the second securing mechanism comprises a blade connector in the second PCB having a plurality of blades; 
 wherein the plurality of pins are configured to engage a blade in the blade connector. 
 
     
     
       3. The mesh network of  claim 1  wherein the electrical coupling comprises an electrical power line and a data transmission line. 
     
     
       4. The mesh network as in  claim 2  wherein:
 the pin connector comprises a pin latching detent configured to engage a blade latching detent in the blade connector; 
 the pin connector is disposed relating to the blade connector at a non-zero offset angle. 
 
     
     
       5. The mesh network as in  claim 2  wherein:
 the pin connector is coupled to a bypass component; and 
 one of the first PCB and the second PCB further comprise a collection pin to provide an electrical power line and a data transmission line to a board controlling an active electrical component. 
 
     
     
       6. The mesh network as in  claim 2  wherein at least one of the pin connector and the blade connector are hinged on a substrate of the first PCB or the second PCB. 
     
     
       7. The mesh network of  claim 2  further comprising:
 a first recess proximal to the pin connector in the first PCB; and 
 a second recess proximal to the blade connector in the second PCB. 
 
     
     
       8. The mesh network of  claim 7  wherein the first recess and the second recess are configured to provide a torsional stress relief to the interlocking connection. 
     
     
       9. A substrate fabric comprising:
 first and second adjacent substrates linked together to form a meshed network, each comprising:
 a first linkable element and a second linkable element, each linkable element including a conductive material, wherein the first linkable element in the first adjacent substrate engages the second linkable element in the second adjacent substrate to define an interlocking connection, the interlocking connection being located at a first side of the first substrate and a second side of the second substrate; 
 wherein the first and second adjacent substrates form a twist angle at the interlocking connection in response to a torsion applied about an axis, and the axis extends transverse to the first side of the first substrate and the second side of the second substrate; and 
 
 a plurality of traces for electrical power and data transmission lines, each of the traces including at least one electrical connection formed between the first linkable element engaging the second linkable element in the first and second adjacent substrates. 
 
     
     
       10. The substrate fabric of  claim 9  wherein the meshed network forms a three-dimensional surface and each of the substrates includes a plug and play electronic device. 
     
     
       11. The substrate fabric of  claim 9  wherein the meshed network has an ergonomic shape. 
     
     
       12. The substrate fabric of  claim 11  wherein the ergonomic shape is compliant with a part of the human body. 
     
     
       13. The substrate fabric of  claim 9  wherein the first and second adjacent substrates comprise at least one of the group consisting of a microphone, a speakerphone, a display, and a touch sensitive screen. 
     
     
       14. The substrate fabric of  claim 9  wherein the first and second adjacent substrates comprise at least one of the group consisting of a pressure sensor and a temperature sensor.

Description:
TECHNICAL FIELD 
     Embodiments described herein relate generally to devices, systems and methods for linking a plurality of electronic boards in non-planar configurations and more particularly to connectors and connector assemblies for linking at least two printed circuit boards (PCBs) in a non-coplanar configuration. 
     BACKGROUND 
     In the field of consumer electronics, miniaturization of devices has led to configurations where the aggregated effect of multiple small devices may provide a more powerful and better-integrated performance. Where multiple units are linked together, the linkage between the units should often be strong and compliant to withstand operational stresses and inadvertent shocks. The result is often a configuration where all units are meshed together so that replacement of a single element requires disassembly of the entire configuration. The need to disassemble an aggregated structure when a piece or component fails may lead to replacement of the entire structure upon a single element malfunction. This creates undesirable costs that eventually are reflected in the marketability of the product. 
     Therefore, what is desired is a device having connectors that enable to link multiple devices in a mesh network and allowing the replacement of a single unit within the mesh network, as desired. 
     SUMMARY 
     In a first embodiment a mesh network of printed circuit boards (PCBs) may include a first PCB coupled to a second rigid PCB by way of an interlocking connection. The interlocking connection has a degree of freedom that allows the first and second PCBs to form a twist angle between each other; the interlocking connector configured to provide electrical coupling between active components disposed in each of the first and second PCBs. 
     Another embodiment may take the form of a substrate fabric. In the context of the present disclosure, a substrate fabric is a mesh network of substrates that conforms to a volume with arbitrary shape forming a three-dimensional surface. The substrate fabric may include a plurality of substrates having active electrical components and further including a plurality of substrates linked together to form a curved surface, and at least two adjacent substrates each having a first linkable element and a second linkable element, and each linkable element including a conductive material. Accordingly, the first linkable element in one of the at least two adjacent substrates engages the second linkable element in the other one of the at least two adjacent substrates. The substrate fabric also includes a plurality of traces for electrical power lines and data transmission lines. Each of the traces may have at least one electrical connection formed between the first linkable element engaging the second linkable element in the at least two adjacent substrates. 
     Yet another embodiment may be a method of forming a substrate fabric. The method may include joining two substrates, forming a chain of joined substrates, adapting the chain to a desired shape, and forming a plurality of chains linked together into a fabric. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The described embodiments may be better understood by reference to the following description and the accompanying drawings. Additionally, advantages of the described embodiments may be better understood by reference to the following description and accompanying drawings. These drawings do not limit any changes in form and detail that may be made to the described embodiments. Any such changes do not depart from the spirit and scope of the described embodiments. 
         FIG. 1  illustrates a substrate including board to board connectors for a non-planar configuration, according to some embodiments. 
         FIG. 2A  illustrates a detail of a board to board connector for a substrate in a non-planar configuration, according to some embodiments. 
         FIG. 2B  illustrates a detail of a board to board connector for a substrate in a non-planar configuration, according to some embodiments. 
         FIG. 2C  illustrates a side view of a substrate in a non-planar configuration, according to some embodiments. 
         FIG. 3  illustrates a chain of substrates linked in a non-planar configuration, according to some embodiments. 
         FIG. 4A  illustrates linked substrates including board to board connectors for a non-planar configuration, according to some embodiments. 
         FIG. 4B  illustrates linked substrates including board to board connectors for a non-planar configuration, according to some embodiments. 
         FIG. 5  illustrates a fabric of substrates linked in a non-planar configuration, according to some embodiments. 
         FIG. 6  illustrates placement of a substrate in a non-planar fabric, according to some embodiments. 
         FIG. 7  illustrates a flow chart of steps in a method of forming a substrate fabric in a non-planar configuration, according to some embodiments. 
         FIG. 8  illustrates a flow chart of steps in a method of activating an electronic device including a meshed network of electrical components, according to some embodiments. 
     
    
    
     In the figures, elements referred to with the same or similar reference numerals include the same or similar structure, use, or procedure, as described in the first instance of occurrence of the reference numeral. 
     DETAILED DESCRIPTION 
     Representative applications of methods and apparatuses according to the present application are described in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known processes, elements and/or configurations have not been described in detail in order to avoid unnecessarily obscuring the described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     In the field of consumer electronics, aggregation of multiple miniaturized devices is convenient in order to create more flexible and powerful performance. An aggregated structure or “fabric” of multiple devices may desirably have a non-planar shape, in order to improve performance. In the context of the present disclosure, a fabric is understood as a three-dimensional mesh network that conforms to a volume with arbitrary shape forming a three-dimensional surface. For example, multiple displays may be configured together around a curved surface that better adapts to a body part, such as an arm, a leg, the head, or a part of the human body. In some embodiments a multiplicity of speakerphones may be put together in a fabric that better adapts to the acoustic requirements of certain applications. A fabric of multiple components as disclosed herein may include a speakerphone and a microphone. In some embodiments, a spherical arrangement of speakerphones and microphones may be conveniently adapted for a stereophonic result (such as in a soccer ball configuration). In general, any type of electronic device may be included in a fabric consistent with embodiments disclosed herein. For example, miniaturized sensors may be conformed into fabrics having any desired shapes. A miniaturized sensor may include a pressure sensor, a temperature sensor, or a touch sensor such as a touch sensitive screen, or any combination of the above. Further and according to some embodiments, a sensor may include a biometric sensor to measure bodily temperature, or other parameters associated with a physiological function. 
     Accordingly, adjacent substrates in embodiments consistent with the present disclosure may form non-planar configurations. Non-planar configurations as disclosed herein may include adjacent substrates in planes orthogonal to one another (i.e. forming a 90° angle between the planes). Furthermore, non-planar configurations as disclosed herein may include adjacent substrates in planes non-orthogonal to one another. More generally, a fabric as disclosed herein may include a network mesh of substrates coupled through multiple interconnection paths. The fabric may form a three-dimensional (3D) network mesh of PCBs where a single printed circuit board (PCB) may be extracted, replaced, without compromising the geometry of the overall 3D-mesh or fabric. In that regard, substrates forming a 3D-network mesh as in embodiments disclosed herein may be plug-and-play active electronic devices or sensors. Thus, replacing one of the substrates may have minimal or no impact in the performance of the aggregated system and may not require replacement of the entire system. 
     In some embodiments, substrates arranged in a 3D-mesh network as disclosed herein may be solar panels adapted to have a shape that receives solar radiation at different angles during the passing of the day. 
       FIG. 1  illustrates a substrate  100  including board to board connectors  110  and  120  for a non-planar configuration, according to some embodiments. Substrate  100  includes an active electrical component  150 . Active electrical component  150  may include an acoustic element, such as a speakerphone, or a microphone, or a sensor. In that regard, substrate  100  may include a PCB having active circuitry to control and receive data from active component  150 . Active electrical component  150  may include a transducer, such as a speaker diaphragm, a capacitor, a light emitting diode (LED), or any other active device, sensor, or transducer. 
     Connector  110  typically includes a plurality of contact pins  111  and a securing mechanism, such as a latching detent  112 . Connector  120  includes a plurality of contact blades  121  and another securing mechanism, again such as a latching detent  122 . Accordingly, contact blades  121  of a first substrate  100  are configured to fit within contact pins  111  of a second substrate  100 , the first and second substrates thus forming a link. Without loss of generality, connector  110  may be referred to as a pin connector, to distinguish from connector  120 , referred to as a blade connector. More generally, connector  110  may be referred to as a first connector and connector  120  may be referred to as a second connector. 
     Accordingly, connector  110  in a first substrate matches or fits into connector  120  from a second substrate. In some embodiments, connector  110  may be similar or identical to connector  120 , and in some embodiments connector  110  and connector  120  may differ from each other so that they fit tightly into one another. In that regard, first connector  110  in a substrate  100  and second connector  120  in an adjacent substrate may form an interlocking connection to mechanically and electrically secure substrate  100  to the adjacent substrate. 
     In some embodiments, contact blades  121  may be squeezed tightly between contact pins  111 . The pressure of contact pins  111  onto contact blades  121  provides a force that mechanically couples the first substrate with the second substrate. Latching detents  112  and  122  are configured to pressure fit into each other when a first substrate  100  is coupled to a second substrate through operation of board connectors  110 ,  120 . Thus, when latching detent  112  in the first substrate  110  engages latching detent  122  in the second substrate  120 , the pressure fit provides mechanical coupling for the first substrate with the second substrate, in addition to the engagement between pins  111  and blades  121 . In some embodiments, either one of latching detent  112  and latching detent  122 , or both, may be formed of a hard material such as a plastic, or a metal. Moreover, in some embodiments latching detent  112  and latching detent  122  may protrude out of board  100  further than pins  111  and blades  121 . 
     Pins  111  and blades  121  are electrically coupled to active circuitry in board  100 , providing electrical power and data transmission between board  100  and external devices. Accordingly, in some embodiments pins  111  and blades  121  may be soldered to connector pads inside board  100 . In that regard, pins  111  and blades  121  may be formed of an electrically conductive material such as a metal. In some embodiments connectors  110  and  120  may be hinged onto board  100 , providing a degree of freedom for the relative positioning of the plurality of pins  111  and the plurality of blades  121  relative to a plane including substrate  100 . Thus, pin connector  110  in substrate  100  forms an interlocking connection with blade connector  120  in an adjacent substrate providing a secure mechanical coupling. Also, pin connector  110  and blade connector  120  provide designed flexibility to the relative orientation of a plane including substrate  100  and a plane including the adjacent substrate. Accordingly, coupling through connectors  110  and  120  enables a non-planar configuration between substrate  100  and the adjacent substrate. 
     Although the connector is shown has having a hexagonal shape, it should be understood that the shape of the connector can vary between embodiments and as used in various electronic devices or in other applications. As non-limiting examples, connectors may be round, cylindrical, square, or have any necessary or suitable polyhedron shape. Further, the top and/or bottom surfaces of the connector need not be flat. The foregoing applies to the various embodiments of connectors shown and/or described throughout this document. 
       FIG. 2A  illustrates a detail of a board to board connector for a substrate in a non-planar configuration, according to some embodiments.  FIG. 2A  illustrates connector  110  from a first substrate engaging connector  121  from a second substrate adjacent to the first substrate. Contact pins  111  in connector  110  include a contact feature  210  that presses onto blade contact  121  in connector  120 . Contact feature  210  may be a protrusion or dimple having a spherical shape, or a convex shape. In that regard, pins  111  may resemble a beam with dimples  210  at the end, such that dimples  210  press onto blades  121 . While pressing onto blade  121 , contact pins  111  provide electrical coupling between the first substrate and the second substrate while adapting to a slight misalignment between pins  111  and blades  121 . Contact feature  210  ensures that electrical contact is maintained while allowing for connector  110  and connector  120  to form an angle relative to each other. The angle between connectors may be non-zero (e.g., connectors  110  and  120  may not be parallel), and contact feature  210  may still allow electrical power and data transmission from the first substrate to the second substrate. More generally, the first substrate and the second substrate may be non-planar while contact feature  210  allows electrical coupling between the first substrate and the second substrate. 
       FIG. 2B  illustrates a detail of a board to board connector for a substrate in a non-planar configuration, according to some embodiments.  FIG. 2B  illustrates the end portion of connector  110  engaging the end portion of connector  120 . Contact pins  111 , contact feature  210 , and contact blade  121  are as described in detail above (cf.  FIG. 1  and  FIG. 2A ). A convex protrusion  222  from latching detent  122  fits into a concave indentation in latching detent  112 . One of ordinary skill will recognize that in some embodiments a concave indentation in latching detent  122  fits into a convex protrusion in latching detent  112 . In that regard, latching detent  112  in connector  110  matches with latching detent  122  in connector  120 . Engagement of latching detent  112  with latching detent  122  provides mechanical coupling between connector  110  and connector  120 . As illustrated in  FIG. 2B , latching detent  222  may be a ball-shaped detent to allow for a degree of misalignment between pins  111  and blades  121 . In some embodiments, latching detent  122  may be located in the center of contact  120 , rather than in the edge as illustrated in  FIGS. 1 and 2B . For example, connectors  110  and  120  may have a single latching detent in the center of the interlocking assembly, thus providing a wider degree of twisting between the planes of adjacent substrates. 
     While  FIGS. 2A and 2B  illustrate a single blade  121  in connector  120  and two pins  111  in connector  110 , any number of blades and pins may be included. Furthermore, each connector  110  or  120  may include both electrical power lines and data transmission lines across one, two, or any number of pins and blades. 
       FIG. 2C  illustrates a side view of a substrate in a non-planar configuration, according to some embodiments. Substrate  100  includes board connectors  110  and  120 , a bypass component  220 , a collection pin  230 , a board  250 , and active component  150 . Accordingly, collection pin  230  feeds electrical power and data to board  250  at a single point. Bypass component  220  reduces the impedance of the electrical power and data channels through a plurality of substrates  100  linked to form a chain. Such configuration having a bypass component may be desirable in applications where a large amount of electrical power flows from connector  110  to connector  120  along an electrical power line. A chain of substrates according to some embodiments will be described in detail in relation to  FIG. 3 , below. 
       FIG. 3  illustrates a chain  300  of substrates  100 - 1  through  100 - 7  linked in a non-planar configuration, according to some embodiments. Substrates  100 - 1 ,  100 - 2 ,  100 - 3 ,  100 - 4 ,  100 - 5 ,  100 - 6 ,  100 - 7  (collectively referred hereinafter as substrates  100 , cf.  FIG. 1 ), are linked together through connectors  110  and  120 . Chain  300  buckles and adopts a compliant shape in curve  310 . Chain  300  also complies with a torsional stress that provides a twisting angle ‘tw’  315  to substrates  100  along the chain. The twisting of chain  300  may be the result of a twist t 1    311  of element  100 - 1  about a reference position (say a horizontal position). And the twisting of chain  300  may also be the result of a twist t 2    312  of element  100 - 7  about the reference position. Accordingly, tw  315  may be the sum of t 1    311  and t 2    312 , i.e., in some embodiments: tw=t 1 +t 2 . Thus, any two adjacent substrates  100  along chain  300  lie in two planes forming a twist angle that is greater than zero. Tw  315  is the addition of all the twist angles between adjacent substrates  100  along chain  300 . 
       FIG. 3  illustrates a force F that may be applied to one of substrates  100  (i.e., substrate  100 - 4 ) to remove it from chain  300 . Accordingly, removal of substrate  100 - 4  may be convenient for replacing, repairing, or updating substrate  100 - 4  without disassembling other substrates  100  from chain  300 . Curve  310  may also indicate a direction of flow of an electrical current providing electrical power to each of substrates  100 . Accordingly, the direction of current flow is not limiting of embodiments consistent with the present disclosure. Moreover, in some embodiments a plurality of electric currents may flow in different directions along curve  310 . The plurality of current flows may include electrical power lines and data transmission lines for substrates  100 . 
       FIG. 4A  illustrates linked substrates  400 - 1 ,  400 - 2 , and  400 - 3  including board to board connectors  110  and  120  for a non-planar configuration, according to some embodiments. Substrates  400 - 1 ,  400 - 2 , and  400 - 3  (collectively referred hereinafter to as substrates  400 ) include recess  410 - 1  and  410 - 2  in the proximity of connectors  110  and  120 , respectively. Recess  410 - 1  is located proximal to pin contact  110 , and recess  410 - 2  is located proximal to blade contact  120 . Recesses  410  provide torsional stress relief to the interlocking connection between substrates  400 . The stress relief allows links formed by substrates  400 - 1 ,  400 - 2 , and  400 - 3  to adopt a non-planar configuration. For example, recess  410 - 1  and recess  410 - 2  are configured to allow substrate  400 - 1  and substrate  400 - 2  to form a twist angle tw (cf. tw  315 ,  FIG. 3 ). Thus, recess  410 - 1  allows each of substrates  400  to be ‘plucked’ in and out of the meshed network without accumulating stress in a PCB board in the substrate. While substrates  400 - 1  and  400 - 2  in  FIG. 4A  have hexagonal profiles forming a non-planar ‘honey-comb’ fabric, this is not limiting of embodiments consistent with the present disclosure. Moreover, one of ordinary skill will recognize that substrates  400 - 1 ,  400 - 2 , and  400 - 3  may have a different shapes and sizes. 
       FIG. 4A  illustrates electric power and data transmission lines  450 - 1 ,  450 - 2 , and  450 - 3  (hereinafter referred to as ‘tracks’  450 ). Tracks  450  provide electrical coupling between connector  120  in one side of substrate  400  and connector  110  in another side of substrate  400 . Accordingly, tracks  450  may follow curved trajectories within substrate  400 . For example, tracks  450 - 2  may end in order to reach from connector  120 - 2  in one side of substrate  400 - 2  to connector  110 - 2  in an adjacent side of substrate  400 - 2 . Moreover, as shown in  FIG. 4A , a substrate  400  may include more than one pin connector  110  or more than one blade connector  120 . Likewise a substrate  400  may include more than one set of tracks. For example, substrate  400 - 2  includes track  450 - 2  coupling blade connector  120 - 2  to pin connector  110 - 2  and track  460 , coupling blade connector  120 - 2  to a second pin connector  410 - 2 . Second pin connector  410 - 2  may be as any one of pin connectors  110  described in detail above (cf.  FIG. 1 ). 
     Accordingly, embodiments of the present disclosure provide a network mesh of substrates  400  electrically and mechanically coupled to each other. In some embodiments, the network mesh is a 3D network mesh where one substrate may be coupled to one, two, or more other substrates. The electrical and mechanical coupling between adjacent substrates may be provided by a pin connector interlocked with a blade connector (e.g., pin connector  110  and blade connector  120 ). In some embodiments, adjacent substrates may include a first connector for mechanical coupling and a second connector for electrical coupling.1 
       FIG. 4B  illustrates linked substrates  470  and  475 - 1  through  475 - 8  (hereinafter referred collectively as substrates  475 ).  FIG. 4B  includes board to board connectors  110 - 1  through  110 - 8 , and  120 - 1  through  120 - 8  for a non-planar configuration, according to some embodiments.  FIG. 4B  illustrates that the relative shape and size of two adjacent substrates in a non-planar configuration as disclosed herein may not be the same. For example, substrate  470  has an octagonal shape, and substrates  475  have a smaller square shape. Connectors  110  and  120  may be ‘pin’ connectors and ‘blade’ connectors, as discussed in detail above (cf.  FIG. 1 ). 
       FIG. 4B  also illustrates electric power lines and data transmission lines along tracks  480 - 1  through  480 - 9  (collectively referred hereinafter as ‘tracks’  480 ). Accordingly, tracks  480  form a complex pattern on substrate  470 . For example, track  480 - 2  may electrically couple substrate  475 - 2  to substrate  470  and to substrate  475 - 3  by splitting into track  475 - 3 . Likewise, substrate  475 - 8  may be electrically coupled to substrate  475 - 6  by merging onto track  480 - 5  in substrate  470 . And substrate  475 - 6  may be electrically coupled to substrate  475 - 7  through tracks  480 - 6  and  480 - 7 . As shown in  FIG. 4B , track  480 - 4  may electrically couple substrates  475 - 4 ,  470 , and  475 - 8 . Electrical coupling as in embodiments disclosed herein may include electrical coupling through a power line, a data transmission line, or both. In that regard, of all the tracks formed in substrate  470  only one, or none, may be coupled to an active circuit in substrate  470  through a collection pin (e.g., collection pin  230 , cf.  FIG. 2C ). 
     Accordingly, substrate  470  may be a node in the meshed network, and each of tracks  48 - 0 - 1  through  480 - 9  may have a different impedance, capacitance, or time response constant. Thus, substrate  470  may draw or distribute electrical power to and from the network through multiple paths. Furthermore, substrate  470  may select a path of least resistance or least capacitance through the meshed network in order to distribute electrical power and data transmission. 
       FIG. 5  illustrates a fabric  500  of substrates linked in a non-planar configuration, according to some embodiments. Fabric  500  includes a plurality of chains  300 - 1 ,  300 - 2 ,  300 - 3 ,  300 - 4 ,  300 - 5 ,  300 - 6 , and  300 - 7 , collectively referred hereinafter as ‘chains’  300  (cf.  FIG. 3 ). Chains  300  adopt curved traces  310 - 1 ,  310 - 2 ,  310 - 3 ,  310 - 4 , and  310 - 5  resulting in a 3D-surface for fabric  500 . Fabric  500  may be adapted to have an ergonomic shape. Fabric  500  may be adapted to have a functional shape, such as a microphone or a speakerphone having stereophonic quality. For example, the surface of fabric  500  may be adapted to conform to an arm, a leg, the torso, or the head of a user. Also, fabric  500  may be shaped to provide an added functionality to the collective operation of active elements  150  in each of substrates  100  included in fabric  500 . In some embodiments fabric  500  may adapt a ball shape approximately spherical. 
     In some embodiments, substrate fabric  500  includes a plurality of substrates  100  having active electrical components and further including a plurality of substrates linked together to form a curved surface, and at least two adjacent substrates each of the two having a first linkable element and a second linkable element. Each linkable element including a conductive material. The first linkable element in one of the at least two adjacent substrates engages the second linkable element in the other one of the at least two adjacent substrates. Accordingly, the first linkable element may be as pin connector  110  (cf.  FIG. 1 ). And the second linkable element may be as blade connector  120  (cf.  FIG. 1 ). 
     In some embodiments, electrical power and data transmission to each of substrates  100  in fabric  500  may follow curves  310  along chains  300 . In some embodiments, electrical power and data transmission to each of substrates  100  in fabric  500  may follow arbitrary trajectories along the surface of fabric  500 . For example, electrical power lines and data transmission lines may follow tracks  520 - 1 ,  520 - 2 ,  520 - 3 , and  520 - 4  (hereinafter referred collectively as tracks  520 ). In that regard, each of the electrical power lines and the data transmission lines include a sequence of substrates  100 . The sequence of substrates may cross over each other, or may be parallel to each other, according to embodiments consistent with the present disclosure. Moreover, the sequence of substrates along one track may include some substrates that belong to another track. For example, track  520 - 3  and track  520 - 2  share substrates  100 - a ,  100 - b , and  100 - c.    
       FIG. 6  illustrates placement of substrate  100 - d  in non-planar fabric  500 , according to some embodiments. A force F is applied so that connector  111  of substrate  100 - d  engages connector  121  in a substrate  100 - 1  adjacent to a first side of substrate  100 - d . Force F also engages connector  121  in substrate  100 - d  to connector  111  in a substrate  100 - 2  adjacent to a second side of substrate  100 - d . In some embodiments, the first side and the second side of substrate  100 - a  may be opposite to each other, along the substrate perimeter. One of ordinary skill will realize that other configurations consistent with the present disclosure may include a first side and a second side in substrate  100 - a  that are adjacent to one another. Accordingly, fabric  500  has electrical power and data transmission lines forming a meshed network such that removing substrate  100 - d  from the fabric does not alter the operation of the entire fabric. Likewise, substrate  100 - d  may include a ‘plug-and-play’ active electronic component such that substrate  100 - d  starts operating as soon as it is placed in position in fabric  500 . In some embodiments, each of the substrates  100  included in fabric  500  may be placed in any desired order without affecting the operation of the entire fabric for its intended purpose. Moreover, fabric  500  may be constantly adapted to have new shapes, or larger shapes and configurations by simply adding more substrates  100  to the meshed network. Furthermore, fabric  500  may be adapted to change its 3D shape by adjusting the twisting angle (e.g., tw  315 , cf.  FIG. 3 ) between adjacent substrates without compromising the electrical coupling between the substrates. Accordingly, in some embodiments fabric  500  has a designed flexibility that allows the 3D structure to adapt to different shapes according to the application. 
       FIG. 7  illustrates a flow chart of steps in a method  700  of forming a substrate fabric in a non-planar configuration, according to some embodiments. The substrate fabric in method  700  may include a plurality of substrates linked into chains (e.g., substrate  100  in  FIG. 1 , chains  300  in  FIG. 3 , and fabric  500  in  FIG. 5 ). Each of the plurality of substrates forming the fabric in method  700  may include a first connector and a second connector (e.g., connector  110  and connector  120 , cf.  FIG. 1 ). Furthermore, in some embodiments the first connector and the second connector may include latch detents to provide a secure mechanical coupling to a link formed between two adjacent substrates in the fabric (e.g. latch detents  112  and  122 , cf.  FIG. 1 ). 
     Step  710  includes joining two substrates to form a link. Accordingly, step  710  may include engaging the first connector in a first substrate with the second connector in a second substrate. For example, in some embodiments step  710  may include squeezing blades in the second connector of the second substrate within pins in the first connector of the first substrate (e.g., blades  121  and pins  111 , cf.  FIG. 1 ). Furthermore, in some embodiments step  710  may include engaging the latching detents in the first connector of the first substrate with the latching detents in the second connector of the second substrate. Thus, step  710  may include interlocking the fingers or protrusions of the first connector and the second connector in adjacent substrates. 
     Step  720  includes forming a chain of joined substrates from a plurality of links formed according to step  710 . Accordingly, step  720  may include forming a first link between the first substrate and a second substrate adjacent to the first substrate as in step  710 . Step  720  may include engaging the first connector in the first substrate to a second connector in the second substrate. Also, step  720  may include repeating step  710  between the first substrate and a third substrate adjacent to the first substrate. Step  720  may include forming a second link between the first substrate and the third substrate. Accordingly, step  720  may include engaging the second connector in the first substrate with a first connector in the third substrate. 
     Step  730  includes adapting the chain to form a meshed network. In some embodiments, step  730  may include providing a twisting angle between the first substrate and the second substrate in step  720  (e.g., tw  315 , cf.  FIG. 3 ). 
     Step  740  includes forming a plurality of chains linked together into a fabric. Accordingly, step  740  may include adapting the fabric into a curved shape having ergonomic properties, as discussed in detail above in relation to fabric  500  (cf.  FIG. 5 ). Adapting the fabric into a curved shape may include a curved shape providing improved functionality to the aggregated effect of the substrates included in the fabric. 
       FIG. 8  illustrates a flow chart of steps in a method  800  of activating an electronic device including a meshed network of electrical components, according to some embodiments. The meshed network in method  800  may include a plurality of substrates linked into chains (e.g., substrate  100  in  FIG. 1 , chains  300  in  FIG. 3 , and fabric  500  in  FIG. 5 ). Each of the plurality of substrates forming the meshed network in method  800  may include a first connector and a second connector (e.g., connector  110  and connector  120 , cf.  FIG. 1 ). Furthermore, in some embodiments the first connector and the second connector may include latch detents to provide a secure mechanical coupling to a link formed between two adjacent substrates in the fabric (e.g. latch detents  112  and  122 , cf.  FIG. 1 ). 
     Step  810  includes providing a plurality of transmission lines through the meshed network. In some embodiments step  810  may include providing an electrical power line and a data transmission line. Step  820  includes dynamically routing at least one of the transmission lines along a selected path. In some embodiments, step  820  may include selecting a path of least resistance in a power transmission line. In some embodiments, step  820  may further include selecting a path of least bit-error-rate in a data transmission line. 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing operations or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20140728
Publication Date: 20170530
Grant Date: 20170530
Priority Date: 20140728
Inventors: BOSSCHER NATHAN P.
STANLEY CRAIG M.
DO TRENT K.
BAKER JOHN J.
HOBSON PHILLIP M.
BOOZER BRAD G.
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K3/36", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/09027", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/038", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/14", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/732", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K1/148", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R35/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/722", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R35/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/722", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/732", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R12/732", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R12/722", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R35/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/36", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 55167455