PATENT DOCUMENT

Publication Number: US-9538662-B2
Application Number: US-201414574191-A
Country: US
Kind Code: B2

Title: 3D flex soldering

Abstract:
In some designs, getting a flexible circuit (flex) to assume a bent state can be helpful in efficiently routing electrically conductive pathways. One efficient way to implement soldering of flexes in a bent state during a reflow operation is to manipulate paneling that hold batches of the flexes to reliably maintain a suitable bend in those flexes. In some embodiments, a flex can be surface mounted to a portion or the whole of an electric device during a reflow operation during which the bent state is maintained by paneling that is at least partially attached to a periphery of the flex. Another solution is to utilize vacuum or hot glue fixtures to maintain a bend in the flex during surface mounting and reflow operations.

Claims:
What is claimed is: 
     
       1. A mobile device, comprising:
 a housing that defines an internal volume; 
 an audio component disposed within the internal volume and coupled to the housing, the audio component comprising a protruding feature positioned between a first lead and a second lead; 
 a flexible circuit, comprising:
 a first surface, comprising a first region soldered to the first lead, a second region soldered to the second lead and a central region disposed between the first and second regions that has a curved geometry that conforms to the protruding feature of the electrical component, 
 a plurality of surface mounted components soldered to a second surface of the flexible circuit and separated by the protruding feature, the second surface being opposite the first surface, and 
 
 traces routed across the central region and electrically connecting the plurality of surface mounted components in support of an output function of the audio component, the central region providing the shortest path for connecting the surface mounted components. 
 
     
     
       2. The mobile device of  claim 1 , wherein the audio component is an audio jack that comprises a monolithic audio jack housing comprising the first region and the second region. 
     
     
       3. The mobile device of  claim 2 , wherein the audio component comprises:
 a first modular connector component comprising the first lead; 
 a second modular connector component comprising the second lead; and 
 a support structure that interlocks with the first and second modular components, a central portion of the support structure being integrally formed with an audio jack barrel, wherein the audio jack barrel comprises the protruding feature. 
 
     
     
       4. The mobile device of  claim 3 , wherein the first and second modular connector components include circuitry for supporting an audio output function of the audio component. 
     
     
       5. The mobile device of  claim 4 , wherein at least one of the first modular connector component or the second modular connector component interacts with the plurality of surface mounted components to support the audio output function. 
     
     
       6. The mobile device of  claim 3 , wherein the support structure defines a plurality of channels each having a size and shape suitable for receiving a portion of the modular connector components. 
     
     
       7. The mobile device  claim 3 , wherein the first modular connector component comprises pins that are electrically coupled with contacts disposed within the support structure. 
     
     
       8. The mobile device of  claim 3 , wherein the audio jack barrel and the curved geometry of the flexible circuit are coaxially aligned. 
     
     
       9. The mobile device of  claim 1 , wherein a trace electrically couples a first one of the plurality of surface mounted components to a second one of the plurality of surface mounted components, and wherein a portion of the trace is disposed on the curved geometry of the central region. 
     
     
       10. The mobile device of  claim 1 , wherein the first one of the plurality of surface mounted components is located proximate the first region and the second one of the plurality of surface mounted components is located proximate the second region. 
     
     
       11. The mobile device of  claim 1 , wherein the central region comprises a gap that facilitates the ability of the flexible circuit to maintain its curved geometry and conform to the protruding portion of the audio component. 
     
     
       12. The mobile device of  claim 1 , wherein routing the traces through the central region includes providing the shortest path between respective surface mounted components taking into account the gap of the central region.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a continuation of International PCT Application No. PCT/US14/70768 filed Dec. 17, 2014, and claims priority to U.S. Provisional Application No. 62/057,706, filed Sep. 30, 2014 and entitled “3D FLEX SOLDERING”, which is incorporated by reference herein in its entirety for all purposes. 
    
    
     FIELD 
     The described embodiments relate generally to a method of manufacturing an electronic device assembly that includes at least one flex circuit. More particularly, the present embodiments relate to techniques for soldering the flex circuit to an electronic component or components while the flex is in a bent state. 
     BACKGROUND 
     As mobile devices continue to get thinner and more features are added, design and packaging requirements become increasingly more difficult to achieve. For example, an amount of space available within a mobile device can decrease when a form factor of the mobile device is reduced. A flexible circuit (flex) can be utilized as a replacement for traditional wires and other connections in order to provide additional space efficiency as well as functionality. In some embodiments, design requirements may dictate that the flex bend around an obstruction. Current flex attachment methods when soldering the flex to various components involve: (1) positioning the components relative to the flex and applying solder paste between each of the components and the flex in a surface mounting step, and (2) heating the flex and the solder until the solder adheres and forms around the electrical connections between the flex and the components in a reflow step. However, conventional manufacturing guidelines dictate the flex remains flat during the entire attachment process. Bending or folding of the flex prior to conducting surface mounting and reflow steps is avoided because, stresses resulting from the bending may cause flattening of the flex and adverse shifting of the components. 
     SUMMARY 
     This paper describes various embodiments that relate to an electronic device assembly apparatus and method for producing an electronic device assembly. More specifically, the electronic device assembly includes a flexible circuit following a particular geometry of an electronic component. 
     A manufacturing method is disclosed. The manufacturing method includes at least the following steps: removing a portion of a carrier attached to a flexible circuit so that a first end of the carrier is separated from a second end of the carrier, the first and second ends of the carrier attached to first and second ends of the flexible circuit; coupling the first end of the carrier to the second end of the carrier; forming an electrical connection between a first portion of the flexible circuit and a first conductive pad and between a second portion of the flexible circuit and a second conductive pad. Coupling the first end and the second end of the carrier together shortens a length of the carrier, which causes a central portion of the flexible circuit to bend. The bend in the central portion of the flexible circuit can accommodate a protruding portion of an electrical component positioned between the first and second conductive pads. 
     Another manufacturing method is disclosed. The other manufacturing method includes the steps of creating a bend in a flexible circuit by manipulating separated portions of a carrier configured to support the flex, the separated portions of the carrier attached to opposing ends of the flexible circuit; maintaining the bend in the flexible circuit by coupling the separated portions of the carrier together; surface mounting a number of components to the flexible circuit; performing a reflow operation on the flexible circuit, the carrier maintaining the bend in the flexible circuit during the reflow operation; and separating the flexible circuit from the separated portions of the carrier. 
     Finally, an apparatus is disclosed. The apparatus includes a flexible circuit with a central region. The flexible circuit can be attached to a carrier. In some embodiments, the flexible circuit is joined to the carrier along a periphery of the flexible circuit. The carrier can include a removable portion attached to the central region of the flexible circuit. The removable portion can be located between a first and second end of the carrier. The interface between the carrier and the flexible circuit can include a number of indicia that are configured to facilitate separation between the removable portion and the carrier by identifying a location of the interface between the removable portion and the ends of the carrier. A length of the carrier is shortened when the removable portion is removed and the first end and the second end are fastened together, thereby creating a bend in the central region of the flexible circuit. 
     An electronic device assembly is disclosed. The electronic device assembly can include an electronic component having a protruding curved surface located between a first lead and a second lead of the electronic component. A flex can electrically couple the first lead and the second lead on the electronic component. The flex can be soldered to the first lead at one end of the flex and also soldered to the second lead at a second end of the flex. A central portion of the flex can be bent to accommodate the protruding curved surface of the electronic device. 
     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 disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIGS. 1A-1D  show top views of an illustrative manufacturing method by which a flex can maintain a bent state during a surface mounting operation and a reflow operation; 
         FIGS. 2A-2C  show cross-sectional views of the illustrative manufacturing method depicted in  FIGS. 1A-1C ; 
         FIGS. 3A-3B  show a number of views of an illustrative electronic device suitable for use with the described embodiments; 
         FIG. 3C  shows a perspective view of an electrical component taking the form of an audio jack assembly suitable for use with the described embodiments; 
         FIG. 3D  shows a perspective view of the audio jack assembly with a flex attached to the audio jack assembly; 
         FIG. 3E  shows a cross-sectional view of the audio jack assembly; 
         FIGS. 4A-4C  show cross-sectional views of another illustrative manufacturing method by which a bent flex can be created and assembled with an electronic component by utilizing a modular electrical component; 
         FIGS. 5A-5B  show cross-sectional views of another illustrative manufacturing method by which a bent flex can be created and assembled with an electronic component by utilizing a vacuum fixture; 
         FIGS. 5C-5D  show cross-sectional views of another illustrative manufacturing method by which a bent flex can be created and assembled with an electronic component by utilizing a hot glue fixture; and 
         FIG. 6  shows a flow chart depicted a manufacturing method during which a flex can maintain a bent state during a surface mounting operation and a reflow operation. 
     
    
    
     DETAILED DESCRIPTION 
     Representative applications of methods and apparatus 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 process steps 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. 
     A flexible circuit (“flex”) is an electronic circuit printed on a flexible polymer substrate often utilized as a connector cable in applications where flexibility, space savings, or other production constraints prevent traditional connectors, such as wires from being utilized. The flex can include a number of electrically conductive pathways that can take the form of leads and traces. In some embodiments, the flex can act solely as a flexible pathway for routing signals, while in other embodiments, one or more electrical components can be surface mounted to the flex at various attachment points. In some embodiments, the attachment points can take the form of electrically conductive leads. The electrical components can be surface mounted to the flex by (1) placing the electrical components in position upon the flex and applying solder paste beneath each of the electrical components in a surface mounting step, and (2) heating the flex and the solder until the solder adheres and forms around the electrical connections in a reflow step. While flexes have increased design efficiencies, traditional flex attachment methods can limit the utility of the flex. For example, an obstacle such as a protruding electrical component or feature can be positioned between two solder pads. Surface mounting a flex to contacts on each of the two pads without routing the flex all the way around the protruding feature would require a portion of the flex to maintain a bent state during the surface mounting to accommodate the protruding component. Plastic deformation due to the bending of the flex can result in an amount of residual force being stored in the flex that biases the flex back towards a flat geometry. Consequently, unless pressure is maintained on each end of the flex, the flex will bend back into a substantially flat state. For this reason, traditional automated assembly line manufacturing processes can be unsuccessful as the residual forces can prevent the ends of the bent flex from being maintained in place during surface mounting and reflow operations. 
     Flexes are commonly mass-produced from a sheet, a rolled up sheet, or a stack of sheets that are large enough to accommodate multiple flexes. Instead of separating each of the flexes from the sheet when the flexes are completed, many manufacturers when delivering large numbers of flexes deliver the flexes without first removing the flexes from the sheet. The sheet is often referred to as a carrier or paneling. In some embodiments, an interface between the paneling and each flex can be limited to small segments of material that join peripheral edges of each flex to the paneling, thereby making the flex easy to remove from the paneling. In some embodiments, the paneling can include extra reinforcement that makes it more rigid than the flexes it supports. 
     One solution to the aforementioned problem of maintaining a bend in the flex during surface mounting and reflow operations, involves a technique in which the paneling is used to maintain the bend in the flex. This solution involves removing a central portion of the paneling that surrounds a central region of a flex. Removing the portion of the paneling surrounding the central region of the flex separates a first portion of the paneling attached to a first end of the flex from a second portion of the paneling attached to a second end of the flex. Subsequent to removing the central portion of the paneling, the first and second portions of the paneling can be moved toward each other until the central region of the flex assumes a bent geometry having a desired size and shape. The first and second portions of the paneling can then be coupled together so the bent geometry can be maintained. The first and second portions can be coupled together by for example high temperature Kapton® (a polyimide substrate) tape or in some embodiments by an extra piece of flex material and glue. Suitable materials for joining the paneling together should be able to maintain the coupling throughout a reflow operation. In some embodiments, removing the central portion of the paneling creates a gap between the first and second portions of the paneling that allows the central region of the flex to define a bent geometry having a predetermined size and shape when the first and second portions of the paneling are brought into abutting contact. Because the paneling leaves both surfaces of the flex exposed, surface mount components can be mounted to both surfaces of the flex. In some embodiments, this configuration can allow surface mounted components to be attached to a first surface of the flex and for a second surface of the flex to be surface mounted to the electrical component that includes a protruding feature. Subsequent to reflow and solidification of the solder, the paneling can be completely cut away from the flex, leaving the flex joined to the electrical component and bypassing the protruding feature. It should be noted that in some embodiments, portions of the paneling that would interfere with the protruding feature of the electrical component can also be cut away prior to conducting surface mounting and reflow operations. 
     In some embodiments, a flex can be surface mounted to modular connectors that include circuitry of an audio jack that connects to the audio jack in a position that places the modular connectors adjacent to a barrel portion of the audio jack. In some embodiments, the flex can be laid out flat on a vacuum fixture that includes a channel in the shape of a desired curve or bend of the flex. When the flex is suctioned to the vacuum fixture a portion of the flex can be secured within and conform with the channel defined by the vacuum fixture. In some embodiments, high temperature adhesive can be used in lieu of or in addition to suction to keep the flex in position upon a fixture. Once the flex is attached to the fixture, solder paste and the electrical component can be placed atop the flex, which can then go through a reflow operation, allowing components to be attached to both surfaces of the flex in a single reflow operation. 
     These and other embodiments are discussed below with reference to  FIGS. 1A-6 ; however, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. 
       FIGS. 1A-1C  show an illustrative method of creating a bend in flex  102  by manipulating paneling  104  so that the bend can be maintained during surface mounting and reflow operations.  FIG. 1A  depicts flex  102  secured to paneling  104 . Paneling  104  can be formed from a rigid, heat-resistant material. In some embodiments paneling  104  can be formed from the same material as at least a portion of flex  102 . The rigid material can include for example, laminates, copper-clad laminates, and pre-impregnated composite fibers. Flex  102  is a flexible circuit that is ordinarily designed to be removed from paneling  104  by cutting through narrow connections extending between a peripheral edge of flex  102  and an edge of paneling  104 ; however, in this embodiment, only some of the narrow connections between paneling  104  and flex  102  are removed. Paneling  104  can also include portion  106  that occupies an opening defined by flex  102 . Removal of portions of paneling  104  from flex  102  can be accomplished by die cutting, laser cutting, milling, or other mechanical cutting operations. In some embodiments, the opening in flex  102  covered by portion  106  can be utilized to reduce an amount of stress generating when bending flex  102 . In some embodiments, the opening occupied by portion  106  can be configured to accommodate a protruding feature positioned proximate to a location upon which flex  102  is configured to be mounted. 
       FIG. 1B  depicts the results of applying a cutting process to partially disconnect flex  102  from paneling  104 . The cutting process for partially disconnecting flex  102  from paneling  104  can split paneling  104  into first portion  108  and second portion  110  so that relative motion between first portion  108  and second portion  110  is restricted only by flex  102 . In this way, flex  102  can bend and flex to accommodate relative motion between first and second portions  108  and  110 . The cutting process leaves gap zones  112 , locator holes  114 , flex opening  116 , and cutouts  118 . Gap zones  112  can be sized to accommodate movement of first portion  108  towards second portions  110 . In some embodiments, gap zone  112  can have a width of about half a millimeter. A distance between first and second portions  108  and  110  defined by gap zone  112  can be commensurate with an amount of bend desired in flex  102 . Locator holes  114  can assist automated machinery in determining a position and orientation of first and second portions  108  and  110 . For example, in some embodiments, the automated machinery can be configured to maneuver first and second portions  108  and  110  so that locator holes  114  overlap one another. Flex opening  116  can reduce an amount of stress generated when bending a central portion of flex  102 . Flex opening  116  can also accommodate protruding features having a size that exceeds the room provided by the curvature of flex  102 .  FIG. 1B  depicts how additional portions of paneling  104  have been removed to form cutouts  118 , which can release a central region of flex  102  from paneling  104 . By freeing the central region of paneling  104  a length over which paneling  104  bends can be clearly defined. In this way, the released central region of flex  102  is left free to bend. In addition to defining an amount of flex  102  that can be bent, cutouts  118  can also be configured to create space for portions of an electrical component that would otherwise interfere with mounting flex  102  to the electrical component. 
       FIG. 1C  shows a top view of flex  102  in a bent state, the bent state achieved by bringing first and second portions  108  and  110  together to form bend  120  and wings  122 . Bend  120  being the portion of flex  102  that defines the bend and wings  122  being the portions of flex  102  that remain substantially flat. It should be noted that while first and second portions  108  and  110  are shown in abutting contact, other configurations are also possible. For example, in some embodiments, gap zones  112  are only shortened, leaving a distance between first portions  108  and second portion  110  and in other embodiments, first and second portions  108  and  110  partially overlap one another. Similarly, first and second portions  108  and  110  can be brought together in various ways. In some embodiments, first portion  108  can be held in place while second portion  110  is pushed towards first portion  108 . In some embodiments, second portion  110  can be held in place while first portion  108  is pushed towards second portion  110 . In other embodiments, first portion  108  and second portion  110  of paneling  104  may be simultaneously pushed together in order to close or reduce gap zones  112 . In some embodiments, locator holes  114  can be utilized to align protruding ends of first and second portions  108  and  110  so that no twist is introduced in flex  102  during the motion. In some embodiments, bend  120  can assume a bent geometry that follows an external curvature of a barrel portion of an audio jack. Once brought together, first portion  108  and second portion  110  can be secured to each other utilizing Kapton® tape, high-temperature adhesive, or interlocking features of first portion  108  second portion  110 . Once bend  120  has been formed and first and second portions  108  and  110  have been securely fixed together, flex  102  can undergo surface mounting and reflow steps while the first and second portions  108  and  110  maintain a geometry of bend  120  in order to surface mount various electrical components, such as the audio jack. In some embodiments, the width and length of cutout  118  can allow various features of the electrical components to pass through cutout  118 , thereby preventing first and second portions  108  and  110  from interfering with positioning flex  102  atop the electrical component prior to the surface mounting and reflow steps. 
       FIG. 1D  shows a number of flexes  102  attached to paneling  104  in a grid pattern in which various ones of flexes  102  are in vertical or horizontal alignment. In some embodiments, paneling  104  can be formed from a rigid material configured to maintain flexes  102  in a substantially flat state. In some embodiments, flexes  102  can be arranged in a pattern limited to one or more columns and rows. Portions of paneling  104  can be removed by a cutting process applied along indicia  152  in order to form gap zones  112  to facilitate forming bends in each of flexes  102 . Removal of material from between indicia  152  allows bending to be concurrently applied to each flex  102  attached to paneling  104 . For example, by moving outbound separated portions of paneling  104  towards the central portion of paneling  104 , bending can be applied to eight flexes  102  in a single step. In some embodiments, indicia  152  can be markings identifiable by a computer vision system so that cuts made by a computer controlled manufacturing apparatus can cut precisely along indicia  152 , thereby separating a central portion of paneling  104  so that opposing sides of paneling  104  can be separated and subsequently manipulated. In this way, indicia  152  can help to define an amount of material removed from paneling  104  so that a bend formed in each of the flexes is maintained at a consistent size and shape. In some embodiments, indicia  152  can be embodied as perforations. A technician can selectively separate flex  102  from paneling  104  by applying a force along an interface between each flex  102  and paneling  104  in accordance with indicia  152  when the indicia are embodied as perforations. In some embodiments, paneling  104  can be referred to as a carrier. Other portions of paneling  104  can be removed from around each flex  102  in a similar manner as described with  FIGS. 1A-1C . 
       FIGS. 2A-2C  show simplified cross-sectional views of  FIGS. 1A-1C  depicting a method for bending a flex.  FIG. 2A  shows a cross-sectional view of paneling  104  and flex  102  in accordance with section line A-A of  FIG. 1A . Flex  102  is depicted in a substantially flat state within paneling  104 .  FIG. 2B  shows a cross-sectional view of flex  102  and paneling  104  in accordance with section line B-B. After undergoing a cutting operation, flex  102  is attached to paneling  104  only at wings  122 . Kapton® tape or high temperature adhesive can be utilized to fix a geometry of bend  120  once the remaining portions of paneling  104  are pushed together by securing the remaining portions of paneling  104  together. In this way, a residual force stored in flex  102  can be prevented from biasing flex  102  back into a flat geometry. In some embodiments, paneling  104  can include interlocking features that allow it to be attached to itself to maintain bend  120  after a central portion of paneling  104  is removed.  FIG. 2C  depicts the final step of attaching flex  102  to electrical component  202 . Electrical component can include protruding feature  204  located between contact points  206 . Bend  120  on flex  102  can curve around protruding feature  204  allowing flat portions of flex  102  to be soldered to contact points  206 . In some embodiments, electrical component  202  can have multiple protruding features, which can be accommodated by one or more flexes  102 . In some embodiments, contact points  206  can be solder pads electrically coupled with circuitry of electrical component  202 . Electrical component  202  can be surface mounted to flex  102  during surface mounting and reflow operations. In some embodiments, the heat involved in reflow can reduce an amount of stress in flex  102  due to bend  120 , thereby reducing an amount of residual stress applied to the connections formed at contact points  206 . After undergoing the surface mounting and reflow steps, both ends of flex  102  are now electrically and mechanically attached to electrical component  202 , and consequently flex  102  can be mechanically separated from paneling  104  without releasing bend  120  from flex  102 . 
       FIGS. 3A-3B  show a mobile device suitable for use with the previously described embodiments. In some embodiments, mobile device  300  can be a mobile telephony device along the lines of a mobile telephone.  FIG. 3A  shows how mobile device  300  can include housing  302  made up of a number of integrally formed walls that cooperate to create an internal volume within which electrical components can be positioned and protected. The electronic components can include circuitry for supporting audio output functionality. Housing  302  can also take the form of multiple housing components that cooperate to define the internal volume for positioning and protecting the electronic components. Housing  302  can also include an opening, which can take the form of opening  304  for receiving an audio cable.  FIG. 3B  shows a top view of mobile device  300  and a close up cutaway view of audio jack assembly  350 . Audio jack assembly  350  can include flex  352  having surface mounted components  354  attached. Flex  352  can include bend  356  defined by flex  352  that accommodates a protruding feature (not depicted) of audio jack assembly  350 . 
       FIG. 3C  shows a perspective view of audio jack assembly  350  pictured without flex  352  attached. Audio jack assembly  350  can include audio jack  358 . Audio jack  358  can include attachment points  360 . In some embodiments, attachment points  360  may need to be electrically coupled together in order for audio jack assembly  350  to provide audio functionality. In some embodiments, attachment points  360  can be solder pads. In some embodiments, minimizing a length of the electrical connections between attachment points  360  can be desirable. For example, audio jack assembly  350  may provide superior audio functionality when a length of electrically conductive pathways joining attachment points  360  is minimized. Audio jack  358  can also include a protruding feature taking the form of barrel  362  that accepts a male end of an audio cable. Barrel  362  can include curved surface  364 . Connecting attachment points  360  in the shortest distance possible can require a flex with a bend such as flex  352  (not shown) in order to electrically couple attachment points (solder pads)  360  disposed upon opposite sides of barrel  362 . 
       FIG. 3D  shows flex  352  electrically coupled to a number of surface mounted components  354 . Flex  352  can include traces  366  for electrically connecting surface mounted components  354  to each other. Surface mounted components  354  can be attached to flex  352  via surface mounting and reflow steps. Flex  352  can include various geometries for minimizing an amount of volume taken up by audio jack assembly  350 . In some embodiments, bend  356  of flex  352  conforms to curved surface  364  of barrel  362  of audio jack  358 . In other embodiments, traces  366  can be routed across bend  356  can provide the shortest path to connect surface mounted components  354  to each other. 
       FIG. 3E  shows a cross-sectional view of audio jack assembly  350  in accordance with section line C-C of  FIG. 3B . Flex  352  can include bend  356  and relatively flat wings  368 . Audio jack  358  can include attachment points  360  for attaching a substantially flat surface such as wings  368  of flex  352  to audio jack  358 . In some embodiments, flex  352  can electrically connect one attachment point  360  to another attachment point  360 . Soldering of flex  352  to attachment points  360  also provide a mechanical connection between audio jack  358  and flex  352 . Attachment points  360  can be contacts or solder points. The mechanical and physical connections can be provided by a solder such as a solder paste. Bend  356  in flex  352  allows flex  352  to curve around barrel  362  of audio jack  358 . In some embodiments, bend  356  of flex  352  remains in physical contact with audio jack  358 . In other embodiments, there can be space between flex  352  and audio jack  358  at bend  356 . 
       FIGS. 4A-4C  depict a method of attaching a component to a flex in a flat state and then forming a bend on the flex and attaching the flex to an electrical component with two of the attached components.  FIG. 4A  shows audio jack assembly  400 . In this embodiment, operational circuitry of audio jack assembly  400  can be integrated into each one of modular connector components  402 . For example, some of the operational circuitry can interact with circuitry of other components of the audio jack assembly to perform an audio output function. Modular connector components  402  can be soldered to flex  404 . Flex  404  can also include surface mount components  406  attached to a surface of flex  404  opposite modular connector components  402 . In some embodiments, flex  404  can maintain a substantially flat state during the surface mounting operation. Modular connector components  402  can include interlocking features  408  to facilitate joining with another part of audio jack assembly  400 . In some embodiments, interlocking features  408  can take the form of pins that electrically couple with the other portions of audio jack assembly  400  such as a number of channels or sockets configured to accept the pins. Modular connector components  402  can utilize attachment points  410  for attachment to flex  404 . Attachment points  410  can take the form of solder pads. 
       FIG. 4B  shows modular connector components  402  being attached to support structure  418  of audio jack assembly  400 . In addition to modular connector components  402 , audio jack assembly  400  can include an electrical component with a protrusion with a curved surface such as audio jack barrel  412 . A technician or machine can apply forces  414  to various components of audio jack assembly  400 . Forces  414  can cooperate to form bend  416  in flex  404  to follow the curved surface of audio jack barrel  412 . Forces  414  can also bring modular connector components  402  to mate with audio jack barrel  412 . Support structure  418  can be integrally formed with audio jack barrel  412  and can mate with interlocking features  408  of modular connector components  402 . Support structure  418  can also electrically couple modular connector components  402  with audio jack barrel  412 . Support structure  418  can also be mechanically strong enough to resist the tendency of flex  404  to return to a substantially flat state.  FIG. 4C  shows flex  404  coupled with audio jack barrel  412  by way of modular connector components  402  to form audio jack assembly  400 . Audio jack barrel  412  can line up coaxially with bend  416 . Flex  404  can contact audio jack barrel  412  at bend  416  or there may be substantial tolerance between flex  404  and audio jack barrel  412 . 
       FIGS. 5A-5B  depict another method of forming a bend in flex  500  and then attaching flex  500  to an electrical component. The method can be utilized on flex  500  to form bend  502  and wings  504 . Flex  500  can start out as a substantially flat piece as depicted in  FIG. 5A . Flex  500  can be laid out onto fixture  506 . In some embodiments, fixture  506  can be a vacuum fixture. Flex  500  can be fixed to fixture  506  at wings  504 . In other embodiments, flex  500  can be secured by a vacuum force created by fixture  506  at the interface between wings  504  and fixture  506 . Fixture  506  can include a channel, which can take the form of gap zone  508 . Gap zone  508  can be formed to create bend  502  when suction is applied to flex  500  by fixture  506 . In some embodiments, gap zone  508  can have a width of about half a millimeter. Audio jack  510  can be attached to flex  500  via attachment points  512 . In some embodiments, attachment points  512  can be solder points and audio jack  510  can be attached to flex  500  by utilizing surface mounting and reflow operations. Bend  502  can also be set by the surface mounting and reflow steps. After undergoing the surface mounting and reflow steps, flex  500  can be mechanically separated from fixture  506 . In some embodiments, attachment points  512  can provide both electrical and mechanical connections between audio jack  510  and flex  500 . 
       FIGS. 5C-5D  depict another method of forming a bend on a flex and then attaching the flex to an electrical component. The method can be utilized on flex  500  to form bend  502  and wings  504 . Flex  500  can start out as a substantially flat piece as depicted in  FIG. 5C . Flex  500  can be laid out onto fixture  506 . In some embodiments, fixture  506  can be a hot glue fixture. Flex  500  can be adhesively coupled to fixture  506  at wings  504  by high temperature resistant glue. Fixture  506  can include a channel, which can take the form of gap zone  508 . Gap zone  508  can be formed to define bend  502  as hot glue layer  514  fixes bend  502  in position within gap zone  508 . In some embodiments, gap zone  508  can have a width of about half a millimeter. Audio jack  510  can be attached to wings  504  via attachment points  512 . In some embodiments, attachment points  512  can be solder points and audio jack  510  can be attached to flex  500  by utilizing surface mounting and reflow steps. After undergoing the surface mounting and reflow steps, flex  500  can be mechanically separated from fixture  506 . Audio jack  510  can include attachment points  512  for attaching a substantially flat surface of flex  500  to audio jack  510 . In some embodiments, flex  500  can electrically connect one attachment point  512  to another attachment point  512 . In other embodiments, attachment points  512  can provide a mechanical connection between audio jack  510  and flex  500 . Attachment points  512  can be contacts or solder points. 
       FIG. 6  shows a flowchart depicting a manufacturing method  600  for creating an electronic device assembly. Step  602  includes creating a bend in a portion of a flexible circuit (flex). The flex can be attached to paneling formed of a rigid material. In some embodiments, the flex can be connected to the rigid material at particular points in order to facilitate easy separation of the flex from the paneling. A central portion of the paneling can be removed, which allows separated portions of the paneling to be manipulated in a way that arranges the flex into a stable bent state. Step  604  includes surface mounting components to the flex. In some embodiments, one of the components can be an audio jack assembly. The bend in the flex can conform to a protruding feature of the audio jack assembly. Step  606  includes performing a reflow operation on the flex and surface mounted components to form a soldered connection between the flex and the surface mounted components. Step  608  includes removing the paneling from the flex. 
     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: 20141217
Publication Date: 20170103
Grant Date: 20170103
Priority Date: 20140930
Inventors: BESEN RICHARD A.
BATES ERIC W.
STEPHENS GREGORY N.
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K2201/10333", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/3436", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/3431", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/2036", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/2036", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10333", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K3/3436", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/3436", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y02P70/50", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/3431", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/3431", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/2036", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R12/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10333", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y02P70/50", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 55586034