PATENT DOCUMENT

Publication Number: US-9713851-B2
Application Number: US-201314078412-A
Country: US
Kind Code: B2

Title: Method and system for attaching flexible circuits to a mounting surface

Abstract:
A method and system for securing a flexible circuit to a mounting structure is disclosed. The system can include a surface-mount device, flexible circuit, stiffener, and bracket. The stiffener is used as an intermediate coupling device between the flexible circuit and bracket. The flexible circuit is coupled to the stiffener with a heat-activated adhesive. Next, the surface-mount device is mounted to the flexible circuit with surface-mounting techniques. A peripheral area of the stiffener is then welded to the bracket. The bracket in turn can be fastened to the enclosure of an electronic device.

Claims:
What is claimed is: 
     
       1. A securing assembly suitable for securing a component to a mounting surface of an enclosure of an electronic device, the securing assembly comprising:
 a flexible circuit having a first surface and a second surface, the first surface opposite the second surface; 
 a surface-mount device electrically coupled with the flexible circuit at the first surface; 
 a securing element coupled with the flexible circuit at the second surface, the securing element comprising a securing element hole and a first welding point, the securing element further comprising a first end having a first curved perimeter and a second end opposite the first end, the second end having a second curved perimeter different than the first curved perimeter; 
 a bracket comprising an indentation into the bracket, the indentation having a first section having a first shape corresponding to the first curved perimeter, the indentation further having a second section having a second shape corresponding to the second curved perimeter such that the bracket receives the securing element at the indentation, the bracket further comprising a bracket hole aligned with the securing element hole such that the bracket hole and the securing element hole; and 
 a fastener that passes through the bracket hole and the securing element hole and secures the surface-mount device with the mounting surface, wherein the indentation comprises a second welding point aligned with the first welding to join the securing element with the bracket by a weld. 
 
     
     
       2. The securing assembly as recited in  claim 1 , wherein the indentation comprises a rounded feature that aligns a corresponding rounded feature of the securing element with respect to the bracket. 
     
     
       3. The securing assembly as recited in  claim 1 , wherein the bracket is separate from the enclosure. 
     
     
       4. The securing assembly of  claim 1 , wherein the flexible circuit defines an outer perimeter on the securing element when the flexible circuit is coupled to the securing element, and wherein the first welding point is external with respect to the outer perimeter. 
     
     
       5. The securing assembly as recited in  claim 1 , further comprising a third welding point located on the securing element that aligns with a fourth welding point on the bracket, wherein the flexible circuit comprises a contoured region to expose the third welding point. 
     
     
       6. The securing assembly as recited in  claim 5 , wherein the third welding point is secured with the fourth welding point by a weld. 
     
     
       7. The securing assembly as recited in  claim 6 , wherein the flexible circuit defines an outer perimeter when positioned on the securing element, wherein the securing element hole, the first welding point, the second welding point, the third welding point, and the fourth welding point are disposed in a location external with respect to the outer perimeter. 
     
     
       8. The securing assembly as recited in  claim 7 , wherein the outer perimeter defines the contoured region, and wherein the third welding point and the fourth welding point are in a location corresponding to the contoured region. 
     
     
       9. The securing assembly as recited in  claim 1 , wherein the bracket hole comprises a through hole disposed in the recessed portion. 
     
     
       10. An electronic device, comprising:
 an enclosure having an inside surface; 
 a securing assembly carried by the enclosure and coupled with the inside surface, the securing assembly comprising:
 a flexible circuit having a first surface and a second surface opposite the second surface, 
 a surface-mount device electrically coupled with the flexible circuit at the first surface, 
 a securing element coupled with the flexible circuit at the second surface, and the securing element comprises a first end having a rounded perimeter and a second end opposite the first end, the second end having a linear perimeter, and 
 a bracket separate from the enclosure and aligned with the second surface, the bracket comprising an indentation in the bracket, the indentation having a size and a shape in accordance with that of the securing element such that the securing element is positioned in the bracket at the indentation and enclosed between the bracket and the flexible circuit, the indentation includes a first section having a first shape corresponding to the having a rounded perimeter, the indentation further having a second section having a second shape corresponding to the linear perimeter such that the bracket receives the securing element at the indentation, wherein the indentation comprises bracket welding points that surround a bracket opening, and wherein the securing element comprises securing element welding points aligned with the bracket welding points and surrounding a securing element opening. 
 
 
     
     
       11. The electronic device as recited in  claim 10 , wherein the bracket is removably coupled with the enclosure by a hook. 
     
     
       12. The electronic device as recited in  claim 10 , wherein:
 the bracket comprises a bracket hole, 
 the securing element comprises a securing element hole, and 
 the inside surface comprises a surface hole aligned with the bracket hole and the securing element hole to allow a fastener to pass through the bracket hole, the securing element hole, and the surface hole. 
 
     
     
       13. The electronic device as recited in  claim 10 , wherein the securing element is secured with the bracket by a first weld at a first welding location and by a second well at a second welding location opposite the first welding location, and wherein the first welding location and the second welding location are external with respect to a location on the securing element occupied by the second surface of the flexible circuit. 
     
     
       14. The electronic device as recited in  claim 13 , wherein:
 the securing element comprises a securing element opening, 
 the bracket comprises a first bracket opening aligned with the securing element opening and between the first welding location and the second welding location, and 
 the bracket comprises a second bracket opening external with respect to the first welding location and the second welding location. 
 
     
     
       15. The electronic device as recited in  claim 13 , wherein the bracket comprises a hook that combines with the second bracket opening to the bracket with the inside surface. 
     
     
       16. The electronic device as recited in  claim 10 , wherein the bracket welding points are welded with the securing element welding points to secure the bracket with the securing element.

Description:
CROSS-REFERENCE TO OTHER APPLICATIONS 
     This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 61/873,785 entitled “METHOD AND SYSTEM FOR ATTACHING FLEXIBLE CIRCUITS TO BRACKETS” filed on Sep. 4, 2013, which is incorporated herein by reference in its entirety for all purposes. 
    
    
     FIELD OF THE DESCRIBED EMBODIMENTS 
     The described embodiments relate generally to securing flexible electronics within an electronic device. In particular methods and systems for securing a flexible circuit to a bracket or to a portion of a device enclosure are described. 
     BACKGROUND 
     Flexible circuits can be secured to various components within an electronic device using pressure sensitive adhesive. The strength of pressure sensitive adhesive is proportional to the surface area over which the adhesive is applied. As portable electronic devices become smaller, the components used in these devices also become smaller. Consequently, the surface area available for pressure sensitive adhesive is limited and in many cases may not be large enough to adequately secure the flexible circuit. 
     Therefore, what is desired is a reliable way to secure flexible circuits within an electronic device. 
     SUMMARY OF THE DESCRIBED EMBODIMENTS 
     This paper describes various embodiments that relate to securing flexible electronics within a device enclosure. 
     In a first embodiment a method for securing a flexible circuit to a mounting structure within an electronic device is disclosed. The method includes at least the following steps: coupling a securing element to a first surface of the flexible circuit using a heat-activated adhesive; soldering a surface-mount device to a second surface of the flexible circuit; and laser welding a portion of the securing element to the mounting structure. The laser welding operation is conducted at a distance from the surface-mount device such that the solder used to attach the surface-mount device to the second surface of the flexible circuit is not reflowed during the laser welding operation. It should be noted that the second surface of the flexible circuit is opposite the first surface of the flexible circuit. 
     In another embodiment, a securing assembly is disclosed. The securing assembly is suitable for securing a flexible circuit to a mounting surface. The mounting surface can be within an inside surface of a device enclosure. The securing assembly includes a flexible circuit, a securing element, a surface-mounted device, and a bracket. The flexible circuit can have a first and second surface, the first surface being opposite the second surface. The surface-mount device is soldered to the first surface of the flexible circuit and the securing element is coupled to the second surface of the flexible circuit by a heat-activated adhesive. Furthermore, the securing element is welded to the bracket. The bracket is configured to be coupled to the mounting surface. 
     In another embodiment, an electronic device is disclosed. The electronic device includes an enclosure having an inside surface, a securing assembly, and one or more surface mount devices. A portion of the inside surface can be detachably coupled to the securing assembly. The securing assembly includes a flexible circuit, a securing element, and a mounting structure. The flexible circuit can have a first surface and a second surface; the first surface opposite the second surface. A surface mount device can be soldered to second surface while the securing element can be coupled to the first surface by a heat-activated adhesive. The securing element can also be welded to the mounting structure. In one aspect of the embodiment the inside surface, mounting structure, and securing element can each an opening, the openings can correspond and can be configured to receive a fastener. 
     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  shows an exploded view of a securing system in accordance with the described embodiments. 
         FIG. 2  shows a bracket and a stiffener. 
         FIG. 3  shows a flexible circuit attached to a stiffener. 
         FIG. 4  shows a folded flexible circuit attached to a stiffener and a surface-mount device. 
         FIG. 5  shows a folded flexible circuit, a stiffener, and a surface-mount device attached and a bracket. 
         FIG. 6  shows a perspective view of the securing system of  FIG. 1  when all components are attached. 
         FIG. 7  shows a flowchart detailing a process in accordance with the described embodiments. 
     
    
    
     DETAILED DESCRIPTION OF SELECTED EMBODIMENTS 
     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. 
     Flexible electronics, also commonly known as flexible circuits, are generally embodied as flexible plastic substrates upon which conductive traces are printed. In some embodiments a flexible circuit can be single layer while in other embodiments a multi-layer flexible circuit can be constructed. In other embodiments a flexible circuit can be configured to allow access to conductive traces and other features from both sides of the flexible circuit. For example, either side of the flexible circuit can be grounded to a conductive surface to which it is attached. Because of their ability to conform to a desired shape or flex during use, flexible circuits can be suitable for routing signals between components disposed within a small electrical device. In some embodiments, an electronic component can be surface-mounted directly onto a surface of a flexible circuit. Surface mountable electronic components are often referred to as surface-mount devices (SMD). 
     Flexible circuits can be supported and/or mounted to a portion of the electronic device using an adhesive. For example a pressure sensitive adhesive can be applied between a surface area of the flexible circuit and a mounting surface within the electronic device configured to receive the flexible circuit. The mounting surface can be a portion of the electronic device&#39;s enclosure or can be a portion of a mounting structure that is configured to be detachably coupled to the electronic device&#39;s enclosure. The corresponding surface areas can then be pressed against each other to activate the pressure sensitive adhesive. Unfortunately, in certain embodiments, components designed for use in a small enclosure frequently do not have sufficient surface area to maintain a robust adhesive coupling between a mounting surface and a flexible circuit. This can be of particular concern when the adhesive coupling is frequently subjected to normal and/or shear force components as a part of normal operation of a device. For example, a flexible circuit adhesively coupled to a slide switch can undergo significant sheering force during actuation of the slide switch and would consequently benefit from a robust adhesive connection. One solution is to use an adhesive with stronger adhesion per unit area. Many heat-activated adhesives have higher holding forces than pressure sensitive adhesives; however; in some cases, using a heat-activated adhesive to attach a flexible circuit directly to the device enclosure can require too much heat and can cause adverse effects to the flexible circuit and/or SMD. For example, during a heat activated adhesion process solder disposed between an SMD and a flexible circuit can undergo reflow. As the solder reflow between the components is not controlled in such an eventuality, this occurrence can degrade or in some cases sever any electrical coupling that had been formed by the reflowed solder. 
     In one embodiment, this problem can be overcome by securing the flexible circuit to a mounting structure, such as a bracket, using a securing element. That is, the securing element can be used as an intermediate coupling device for securing the flexible circuit to the bracket. In turn, the bracket can be coupled with the device enclosure. Although embodiments throughout this disclosure can describe a mounting structure taking the form of a bracket, it should be understood that this embodiment is not limiting and that mounting structure can be any structure suitable for supporting/mounting a flexible circuit, including the device enclosure. 
     In one aspect of the embodiment, a portion of the securing element is bound to the flexible circuit with a heat-activated adhesive. Subsequently, a portion of the securing element is welded to the bracket. Accordingly, the securing element is made of material suitable for both welding and surface adhesion. Generally, the heat required in a welding operation is proportional to the size of the items welded. Accordingly, reducing the size of one or both of the items to be welded will reduce the heat required in the welding operation. Therefore, to reduce the heat required to weld the securing element to the bracket, the securing element can be smaller than the bracket. For example, the securing element can have less surface area, volume and/or thickness than the bracket. Because the securing element can be used for both welding and surface adhesion, the aforementioned methods and techniques result in a stronger coupling for connecting the flexible circuit with the bracket. 
     In one aspect of the embodiment, the securing element is laminated to one side of the flexible circuit using a heat-activated adhesive. The heat-activated adhesive can be a thin layer of film. Relatively, less surface area is required because heat-activated adhesive has a greater strength of adhesion per surface area than pressure-sensitive adhesive. Additionally, a heat-activated adhesive can be less susceptible to heat than pressure sensitive adhesives. Accordingly, a heat-activated adhesive can be less susceptible to adverse effects from heat emitted during subsequent steps in an assembly process, such as a welding operation, than a pressure sensitive adhesive. Furthermore, an adhesive coupling can also be less susceptible to delamination due to normal heat excursions from normal operation of proximate electrical components. An electronic component, such as an SMD, can then be mounted to the other side of the flexible circuit. In yet another aspect of the embodiment, the SMD can be mounted to a surface of the flexible circuit using surface-mount technology (SMT). After the SMT mounting of the SMD is complete, a portion of the securing element can be welded to the bracket, thereby securing the flexible circuit and SMD with the bracket. 
     These and other embodiments are discussed below with reference to  FIGS. 1-7 ; 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. 
       FIG. 1  shows an exploded view of securing system  100  according to one embodiment. Securing system  100  includes SMD  102 , flexible circuit  104 , securing element  106 , and bracket  108 . Securing system  100  can be used to secure SMD  102  to a device enclosure. SMD  102  can be any device suitable to be mounted on flexible circuit  104 . For example, SMD  102  can be a switch, microphone, connector, etc. In one aspect of the embodiment, SMD  102  can have one or more metal contacts (i.e. terminals) that can be directly soldered to a surface of flexible circuit  104 . For example, SMD  102  can be packaged in a dual-in-line configuration or a ball grid array configuration for soldering SMD  102  directly to solders pads on flexible circuit  104 . 
     Flexible circuit  104  can be a substantially planar substrate configured to support and electrically couple various electrical components. At least one side of flexible circuit  104  can be configured to be coupled with SMD  102 . In one aspect of the embodiment, SMD  102  is mounted on one side of flexible circuit  104  while securing element  106  is coupled to an opposing side of flexible circuit  104 . Flexible circuit  104  can electrically couple SMD  102  to a processor (not shown) of an electronic device. Securing element  106  can take the form a structure suitable for surface adhesion and welding such as a stiffener. Although the following embodiments will describe securing element  106  taking the form of a stiffener from here on out, it should be understood that this embodiment is not limiting and that securing element  106  can take many other forms. 
     Securing element  106  can be configured to have less surface area, volume and/or thickness than bracket  108 . In one embodiment, securing element  106  is about 0.10 mm thick. Bracket  108  includes a surface area for coupling at least a portion of securing element  106  to bracket  108 . In one aspect of the embodiment, bracket  108  is welded to a portion of securing element  106 . Accordingly, at least a portion of bracket  108  is made of weldable material. For example, bracket  108  can be made of steel or aluminum. Bracket  108  can also be coupled to stiffener  106  using a fastener. For example, a fastener can be passed through an opening in securing element  106  and a corresponding opening in bracket  108  and driven into an opening in a device housing configured to receive the fastener until the bracket  108  and securing element  106  are mechanically coupled with the housing. Furthermore, bracket  108  is configured to be removably coupled to a device enclosure or device housing. 
     Securing element  106  can be configured to have less surface area, volume and/or thickness than bracket  108 . In one embodiment, securing element  106  is about 0.10 mm thick. Bracket  108  includes a surface area for coupling at least a portion of securing element  106  to bracket  108 . In one aspect of the embodiment, bracket  108  is welded to a portion of securing element  106 . Accordingly, at least a portion of bracket  108  is made of weldable material. For example, bracket  108  can be made of steel or aluminum. Bracket  108  can also be coupled to stiffener  106  using a fastener. For example, a fastener can be passed through an opening in securing element  106  and a corresponding opening in bracket  108  and driven into an opening in a device housing configured to receive the fastener until the bracket  108  and securing element  106  are mechanically coupled with the housing. Furthermore, bracket  108  is configured to be removably coupled to a device enclosure or device housing. 
       FIG. 2  shows bracket  108  and securing element  106  according to one embodiment. Bracket  108  can include alignment feature  110 , opening  112 , opening  114 , planar portion  116 , indentation  118 , and hook  120 . Bracket  108  is configured to be removably attached to a portion of a device enclosure. For example, openings  112  and  114  can be part of a fastening system for fastening bracket  108  to a device enclosure. During an assembly process, openings  112  and  114  can be aligned with corresponding openings of the device enclosure (not shown). Subsequently, fasteners can be driven through openings  112  and  114  and into the corresponding openings of the device enclosure until bracket  108  is securely fastened to an inside surface of the device enclosure. In some embodiments, the fastener passing through opening  112  can also be utilized to further secure securing element  106  to bracket  108  by passing that fastener through opening  124 . Accordingly, securing element  106  would also be secured with the device enclosure. To further secure bracket  108  to the device enclosure, hook  120  can be used to hook bracket  108  onto a portion of the device enclosure. 
     Securing element  106  can include alignment feature  122  and opening  124 . In one embodiment, alignment feature  122  can be located along a periphery of securing element  106 . In another embodiment, alignment feature  122  can be located at a central portion of securing element  106 . Alignment feature  122  is a feature that can be sized and dimensioned to work in conjunction with alignment feature  110  to correctly align securing element  106  and bracket  108  when assembled. For example, alignment feature  122  can be a portion of securing element  106  that is arched. Accordingly, alignment feature  110  can be dimensioned and sized to have an arched portion that compliments alignment feature  122 . The alignment system of  122  and  110  assists in the assembly procedure by aligning securing element  106  and bracket  108  correctly before they are welded together at welding points  126 . It should be noted that alignment feature  110  can be utilized in conjunction with an assembly fixture for positioning components of the securing system during various phases of assembly of the securing system. 
     Opening  124  can be dimensioned and shaped in accordance with opening  112  such that when securing element  106  and bracket  108  are attached, a fastening device such as a screw can pass through openings  124  and  112 . Accordingly openings  124  and  112  can also be used as an alignment tool to confirm securing element  106  and bracket  108  are aligned correctly before and/or after securing element  106  and bracket  108  are welded together. For example, prior to attachment (e.g., welding operation), alignment can be verified by checking if openings  124  and  112  are aligned such that a fastener can pass through openings  124  and  112 . It should be noted that in some embodiments, securing element  106  can be attached to bracket  108  without a fastener. 
     Planar portion  116  is a substantially planar portion of bracket  108 . Accordingly it is suitable for receiving a substantially planar surface of stiffener  106 . indentation  118  can be portions of bracket  108  that are not co-planar with respect to planar portion  116 . indentation  118  can also be used to assist in aligning and securing elements to be coupled to bracket  108 . For example, indentation  118  can be used to help align and hold bracket  108  and stiffener  106  into place (i.e., a desired alignment with respect to bracket  108  and stiffener  106 ) when they are welded together. For example, when aligning stiffener  106  and bracket  108 , stiffener  106  can be placed adjacent to planar portion  116  and orientated such that openings  112  and  124  are aligned and alignment features  110  and  122  are aligned. During the welding operation, stiffener  106  can be biased toward indentation  118 . Because a portion of indentation  118  is taller/thicker than stiffener  106 , indentation  118  (in conjunction with alignment features  110  and  122 ) can prevent stiffener  106  from moving in one or more directions when welded. indentation  118  can also establish another surface area for receiving other components or devices. For example, indentation  118  can have a surface area suitable for supporting another flexible circuit or another securing element. 
       FIG. 3  shows securing element  106  coupled to one side of flexible circuit  104  in accordance to one embodiment. In one aspect of the embodiment, securing element  106  can be coupled to flexible circuit  104  with a heat-activated adhesive. The heat-activated adhesive can be a film applied between securing element  106  and flexible circuit  104 . For example, a heat-activated adhesive could be a heat sensitive epoxy having a thickness of about 0.02 mm. Any number of processes can be used to couple securing element  106  and flexible circuit  104  with the heat-activated adhesive including lamination, heated pressing, heat gun activation or an oven process. When coupled to flexible circuit  104 , a portion of securing element  106  can protrude from the perimeter of flexible circuit  104 . Portions of securing element  106  that protrude beyond the perimeter of flexible circuit  104  can be used as welding points  126  and visual cues in the alignment process. For example, alignment feature  122  protrudes from one end of flexible circuit  104 . Alignment feature  122  can be used as one or more welding points  126  and as an alignment cue when aligning securing element  106  to bracket  108 . Furthermore, when alignment feature  122  is used as one or more welding points, alignment feature  122  can be configured to be located to be a distance away from SMD  102  (and consequently away from solder pads  130 ) as to not reflow the solder and/or minimize the heat transferred to SMD  102  during the welding operation. 
     Flexible circuit  104  includes one or more solder pads  130  and cut portion  132 . Solder pads  130  can be used to mount SMD  102  to a surface of flexible circuit  104 . Cut portion  132  is a portion of flexible circuit  104  that is cut to uncover exposed portion  128  of securing element  106  for welding (i.e. cut portion  132  exposes one or more welding points  126 ). In one embodiment, cut portion  132  is a trimmed portion of flexible circuit&#39;s perimeter such that cut portion  132  is exposing one end of securing element  106 . In another aspect of the embodiment, cut portion  132  can define an opening located within the body of flexible circuit  104  to expose a portion of securing element  106  remote from flexible circuit&#39;s perimeter. 
       FIG. 4  shows a perspective view of securing element  106  coupled to one side of flexible circuit  104  in accordance with one embodiment. Because the flexible circuit  104  can operate in a bendable and flexed position, flexible circuit  104  can be folded at line A, allowing a first portion of flexible circuit  104  to extend in a different direction relative to a second portion that is attached to securing element  106 . In one embodiment, the first and second portions of flexible circuit  104  relative to line A are substantially orthogonal, allowing the first portion to extend to a portion of the electronic device remote from securing element  106 . Accordingly, the first portion can be used to provide functionality at other portions of the electronic device and/or electrically couple SMD  102  with components remote from SMD  102 . For example, the first portion can extend to and electrically couple with a processor that is remote from SMD  102 . A conductive trace within flexible circuit  104  can be configured to electrically couple SMD  102  with the processor. 
     Solder pads  130  are configured to compliment the leads of SMD  102  such that SMD  102  can be mounted to flexible circuit  104  using surface-mounting techniques. In one embodiment, SMD  102  is mounted on flexible circuit  104  directly opposite of securing element  106 . In this case, securing element  106  can provide SMD  102  with structural support. In another embodiment, SMD  102  can be electrically coupled to a ground reference using any combination of the intermediate elements (flexible circuit  104 , securing element  106 , and bracket  108 ) between SMD  102  and the ground reference. For example, typically a device enclosure made of metal can be used as a chassis ground. SMD  102  is electrically coupled to flexible circuit  104  via solder pads  130 . Flexible circuit  104  can be conductively laminated to securing element  106  such that a signal or electrically conductive grounding path can be established between flexible circuit  104  and securing element  106 . For example, the heat-activated adhesive can include conductive particles allowing electrical signals to pass between the bonded components. Furthermore, securing element  106  can be conductively welded to bracket  108  or conductively connected with bracket  108  via a fastener threaded through openings  124  and  112 . In turn bracket  108  can be conductively fastened to the device enclosure. Accordingly, flexible circuit  104 , securing element  106  and bracket  108  can be configured to provide SMD  102  an electrically conductive grounding path to chassis ground (e.g. the device enclosure). 
       FIG. 5  shows a perspective view of securing system  100  where SMD  102 , flexible circuit  104 , and securing element  106  are coupled and ready to be coupled to bracket  108  in accordance to one embodiment. Securing element  106  can be welded to bracket  108  at welding points  126 . The welding operation is selected in order to minimize the heat transferred to other elements (e.g., flexible circuit  104 , SMD  102 ), as to prevent decoupling between other elements and/or prevent damage to the elements. In one aspect of the embodiment, securing element  106  and bracket  108  are welded together during a laser beam welding operation, such that a highly concentrated, limited amount of heat is applied during the operation. Furthermore, because the heat required in a welding operation can be proportional to the thickness of the objects welded, if the securing element  106  is thin (relative to bracket  108 ), the welding operation can be performed using heat sufficiently low as to not damage flexible circuit  104 /SMD  102  or reflow the solder used to mount SMD  102 . In addition, welding points  126  can be selected to be at portions of securing element  106  that are away from the perimeter of flexible circuit  104  such that welding points  126  are relatively remote from the main body of flexible circuit  104  and SMD  102 . In this way, heat generated by the welding operation can be substantially dissipated across bracket  108  and securing element  106  before coming into contact with the solder used to mount SMD  102 . Consequently, the energy delivered from the welding operation can be minimal enough that the solder does not undergo reflow.  FIG. 6  shows a fully assembled securing system  100  including SMD  102 , flexible circuit  104 , and securing element  106  all securely coupled with bracket  108 . In one embodiment, flexible circuit  104  is bent at line A, where line A corresponds to an edge of bracket  108 . Accordingly, a portion of flexible circuit  104  can be bent to be substantially orthogonal to a surface of bracket  108 . As assembled, securing system  100  can then be fastened to a device enclosure using openings  124 ,  112  and  114  and/or hook  120 . Accordingly, securing system  100  secures SMD  102  within the device enclosure. 
       FIG. 7  is a flow chart detailing a process  700  for securing a flexible circuit to a bracket according to one embodiment. Process  700  beings at  702 , where a portion of the securing element is bound to a surface of a flexible circuit using a heat-activated adhesive. In one aspect of the embodiment, the heat-activated adhesive is an epoxy. Optionally at  704 , a portion of the flexible circuit is contoured to expose a portion of the securing element. Alternatively,  704  can be performed before the securing element is bound to the flexible circuit. Next at  706  an SMD is mounted to a surface of the flexible circuit using surface-mounting techniques. For example, a reflow solder process or wave soldering process can be used to mount the SMD. At  710 , alignment features on the securing element and are aligned with corresponding alignment features on the bracket. Next, a portion of the securing element is welded to the bracket at  712 . Any number of welding techniques can be used including laser welding, resistance welding and ultrasonic welding. In one aspect of the embodiment, securing element is welded to the bracket at the portions of the securing element exposed in  704 . At  714 , the bracket can be coupled to a device enclosure. In some embodiments, the bracket is coupled to the device enclosure by driving one or more fasteners through corresponding openings of the bracket and the device enclosure. In other embodiments, the bracket is coupled to the device enclosure by hooking a portion the device enclosure with a hook of the bracket. Accordingly, at the end of the process  700  the flexible circuit and SMD is securely coupled with the device enclosure. 
     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: 20131112
Publication Date: 20170725
Grant Date: 20170725
Priority Date: 20130904
Inventors: MERZ NICHOLAS G.
MALEK SHAYAN
COHEN SAWYER I.
LUI TIMOTHY
Assignee: APPLE INC
CPC Classifications: [{"code": "B23K2103/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K2101/42", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K2101/18", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K2103/50", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K2103/05", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K2103/04", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10083", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K26/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10053", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/2009", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K1/0016", "inventive": true, "first": true, "tree": "[]"}, {"code": "B23K26/32", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K26/323", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/0061", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K2203/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K2203/04", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K2203/50", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/0061", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K2201/18", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K1/0016", "inventive": true, "first": true, "tree": "[]"}, {"code": "B23K26/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10083", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/2009", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K26/323", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K26/32", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K2203/05", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10053", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K2201/42", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 52582963