PATENT DOCUMENT

Publication Number: US-10034373-B2
Application Number: US-201715406360-A
Country: US
Kind Code: B2

Title: Circuit board secured to battery cell using a circuit board through hole and methods for welding the circuit board

Abstract:
An electronic device having a circuit board and a battery is disclosed. The circuit board may include a through hole and an electrical pad surrounding the through hole. In order to electrically couple the circuit board to the battery, and in particular, an electrode of the battery, a tab (or plaque) is placed between the electrical pad and the electrode. The tab electrically couples with the electrical pad by a soldering operation. To couple (electrically and mechanically) the tab with the electrode, a welding operation is used. The welding operation may include a laser weld providing thermal energy through a laser beam. In this regard, the laser beam passes through the through hole, thereby (partially) melting the tab and forming a weld between the tab and the electrode. Accordingly, the tab covers the through hole such that the tab is positioned to receive the laser beam.

Claims:
What is claimed is: 
     
       1. A printed circuit board, comprising:
 a substrate that includes a trace that is formed of electrically conductive material, the substrate including a first surface and a second surface opposite the first surface, the substrate further including a through hole that extends from a first opening at the first surface to a second opening at the second surface; 
 an electrically conductive pad disposed on the first surface and electrically coupled to the trace, wherein the pad at least partially surrounds the first opening; 
 an electrically conductive tab that is accessible via the through hole and the second opening and that is electrically coupled to the electrically conductive pad, wherein the electrically conductive tab electrically connects a first terminal of an external electrical component to the trace by way of the electrically conductive pad; 
 a second electrically conductive pad; and 
 a spacer that electrically couples the second electrically conductive pad to a second terminal of the external electrical component, the second terminal of the external electrical component positioned non-coplanar with the first terminal of the external electrical component. 
 
     
     
       2. The printed circuit board of  claim 1 , further comprising a weld at a location corresponding to the through hole that bonds the electrically conductive tab with the external electrical component. 
     
     
       3. The printed circuit board of  claim 2 , wherein the weld electrically couples the electrically conductive pad with the external electrical component. 
     
     
       4. The printed circuit board of  claim 1 , wherein the electrically conductive tab covers at least a portion of the first opening at the first surface. 
     
     
       5. The printed circuit board of  claim 4 , wherein the spacer covers the second opening at the second surface. 
     
     
       6. The printed circuit board of  claim 1 , wherein the electrically conductive pad surrounds the first opening at the first surface. 
     
     
       7. The printed circuit board of  claim 6 , wherein the circuit board comprises multiple electrically conductive pads that combine with the electrically conductive pad to surround the first opening at the first surface. 
     
     
       8. An electronic device, comprising:
 a circuit board comprising an opening; 
 a first electrical pad and a second electrical pad disposed on the circuit board; 
 an internal power supply that includes a first electrode and a second electrode; 
 a tab engaging the first electrical pad and the first electrode, wherein the tab bonds with the electrode by a weld, the weld in a location corresponding to the opening; and 
 a spacing element electrically coupling the second electrode with the second electrical pad. 
 
     
     
       9. The electronic device of  claim 8 , wherein the circuit board comprises a first surface and a second surface opposite the first surface, and wherein the tab covers the opening at the first surface. 
     
     
       10. The electronic device of  claim 9 , further comprising a component electrically coupled with the circuit board and covering the opening at the second surface. 
     
     
       11. The electronic device of  claim 10 , wherein the circuit board comprises a stepped profile, and wherein the tab is positioned in the stepped profile such that the tab is co-planar with respect to the second surface. 
     
     
       12. The electronic device of  claim 8 , wherein the spacing element comprises a cantilevered spacing element. 
     
     
       13. The electronic device of  claim 8 , wherein the electrode is non-coplanar with respect to the second electrode. 
     
     
       14. A method for assembling a substrate with an internal component of an electronic device, the internal component comprising a battery that includes a terminal and a second terminal, the substrate having a through hole and an electrical pad at least partially surrounding the through hole, the method comprising:
 engaging a tab with the electrical pad and the terminal of the internal component; 
 inserting a spacing element between the substrate and the internal component such that the spacing element engages a second electrical pad of the substrate and the second terminal; 
 receiving heat through the through hole; and 
 bonding the tab with a terminal of the internal component. 
 
     
     
       15. The method of  claim 14 , wherein receiving the heat through the through hole comprises laser welding the tab and the terminal to form a weld between the tab and the terminal. 
     
     
       16. The method of  claim 14 , further comprising covering the through hole at a surface of the substrate. 
     
     
       17. The method of  claim 16 , further comprising covering the through hole at a second surface of the substrate, the second surface opposite the surface. 
     
     
       18. The method of  claim 17 , wherein covering the through hole at the second surface comprises electrically coupling a second internal component with the second surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/379,174, filed on Aug. 24, 2016, and titled “CIRCUIT BOARD WELDED TO BATTERY CELL USING A CIRCUIT BOARD THROUGH HOLE AND METHODS FOR WELDING THE CIRCUIT BOARD,” the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The following description relates to welding techniques between a circuit board and another component. In particular, the following description relates to welding a circuit board to the component using a through hole of the circuit board. The welding techniques can reduce the number of steps use to secure the circuit board to the component as well as reduce the amount of space occupied by the circuit board and the component, as the circuit board is spaced closer to the component. 
     BACKGROUND 
     Using a tab, a circuit board can be secured to a battery pack, or an electrode of the battery pack. The circuit board and the battery pack may be inserted into an electronic device such as a smartphone. The tab is designed as a bendable tab that bends or folds in a location, and the bendable tab remains in the bend or folded configuration. Initially, the tab is secured to the circuit board and the electrode. Then, the bendable tab is bent, thereby moving and positioning the circuit board next to the battery pack. 
     However, the bendable tab includes several drawbacks. For instances, the bending operation of the tab can lead to inconsistent placement of the circuit board relative to the battery pack. Also, the positioning the circuit board in a desired location relative to the battery pack depends upon the dimensions of the tab. In this regard, individual tabs may vary in thickness (that is, one tab may include a different thickness than another tab), and as a result, the bend radius of the tab may also vary. This may lead to inconsistent placement of the circuit board relative to the battery pack. 
     Furthermore, in regard to spacing between the circuit board and the battery pack, a tab having a thickness T and bent to include a 180-degree bend requires the spacing to be least 2 T, plus any space between the two non-bent areas of the tab. As such, the bending operation may create unwanted spacing, which leads to either additional dedicated room for the circuit board and the battery pack, or a reduced battery pack that provides less power for the electronic device. 
     SUMMARY 
     In one aspect, a printed circuit board is described. The printed circuit board may include a substrate that includes a trace that is formed of electrically conductive material, the substrate including a first surface and a second surface opposite the first surface. The substrate may further include a through hole that extends from a first opening at the first surface to a second opening at the second surface. The printed circuit board may further include an electrically conductive pad disposed on the first surface and electrically coupled to the trace. In some instances, the pad at least partially surrounds the first opening. Also, the printed circuit board may include an electrically conductive tab that is accessible via the through hole and the second opening and that is electrically coupled to the electrically conductive pad. In some embodiments, the electrically conductive tab electrically connects an external electrical component to the trace by way of the electrically conductive pad. 
     In another aspect, an electronic device is described. The electronic device may include a circuit board that includes an opening. The electronic device may further include an electrical pad disposed on the circuit board. The electronic device may further include an internal power supply that includes an electrode. The electronic device may further include a tab engaging the electrical pad and electrode. In some embodiments, the tab bonds with the electrical component by a weld. The weld may be in a location corresponding to the opening. 
     In another aspect, a method for assembling a substrate with an internal component of an electronic device is described. The substrate may include a through hole and an electrical pad at least partially surrounding the through hole. The method may include engaging a tab with the electrical pad and the internal component. The method may further include receiving heat through the through hole. The method may further include bonding the tab with a terminal of the internal component. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       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: 
         FIG. 1  illustrates an isometric view of an embodiment of an electronic device, in accordance with some described embodiments; 
         FIG. 2  illustrates a plan view of the electronic device in  FIG. 1 , showing a substrate and an internal power supply; 
         FIG. 3  illustrates an isometric view of an alternate embodiment of a substrate having a pair of electrical pads in the form of parallel plates; 
         FIG. 4  illustrates an isometric view of an alternate embodiment of a substrate having a pair of electrical pads partially surrounding an opening of the substrate; 
         FIG. 5  illustrates an isometric view of an alternate embodiment of a substrate having multiple electrical pads partially surrounding an opening of the substrate; 
         FIG. 6  illustrates an isometric view of an alternate embodiment of a substrate having an electrical pad surrounding an opening of the substrate; 
         FIG. 7  illustrates a cross sectional view of an embodiment of a substrate, showing the substrate undergoing a reflow operation in order to solder components to the substrate, in accordance with some described embodiments; 
         FIG. 8  illustrates a cross sectional view of the substrate shown in  FIG. 7  subsequent to the reflow operation; 
         FIG. 9  illustrates a cross sectional view of the substrate secured with the internal power supply with the tab positioned against an electrode of the internal power supply; 
         FIG. 10  illustrates a cross sectional view of the substrate and the internal power supply shown in  FIG. 9 , further showing the tab undergoing a bonding operation to weld the tab with the electrode; 
         FIG. 11  illustrates a cross sectional view of the substrate and the internal power supply shown in  FIG. 10 , showing the tab welded with the electrode; 
         FIG. 12  illustrates an isometric view of the substrate and the internal power supply shown in  FIG. 11 , further showing a component secured with the substrate on an opposing surface of the substrate; 
         FIG. 13  illustrates a partial cross sectional view of a substrate secured with an internal power supply by a tab; 
         FIG. 14  illustrates a cross sectional view of a first substrate secured with a second substrate by a pair of tabs welded together; 
         FIG. 15  illustrates a cross sectional view of an embodiment of a tab used to secure a substrate with a housing; 
         FIG. 16  illustrates a cross sectional view of the tab shown in  FIG. 15 , showing the tab pressed against the housing and undergoing a welding operation to weld the tab with the housing; 
         FIG. 17  illustrates a cross sectional view of an embodiment of a tab used to secure a substrate with a housing, further showing a compressible material positioned between the substrate and the housing; 
         FIG. 18  illustrates an isometric view of an embodiment of a spacing element having a dome configuration; 
         FIG. 19  illustrates an isometric view of an alternate embodiment of a spacing element having a cross configuration; 
         FIG. 20  illustrates an isometric view of an alternate embodiment of a spacing element having a cantilevered configuration; and 
         FIG. 21  illustrates a flowchart showing a method for assembling a circuit board with an internal component of an electronic device, in accordance with some described embodiments. 
     
    
    
     Those skilled in the art will appreciate and understand that, according to common practice, various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     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. 
     The following disclosure relates to an electronic device that includes a circuit board coupled to a battery by a tab. The circuit board may include an opening, or through hole, that allows for a welding operation to bond the tab with the battery, and in particular, a battery electrode of the battery. The welding operation may include laser welding, as a non-limiting example. Using the opening for the bonding operation, the tab may not require any folding or bending to position the circuit board, thereby reducing the number of operation steps and eliminating improper placement of the circuit board due to the bending of the tab. As a result, the circuit board can be mounted in a desired location and then bonded with the battery electrode by the bonding operation. This may also save space in the electronic device, as the tab may include a generally flat or planar tab, as opposed to a folded tab that includes two non-bent portions facing each other. Moreover, the flat tab may include less material and provide a cost savings as well reduce the overall weight of the electronic device. 
     In some instances, when the circuit board is coupled with the battery electrode, the circuit board is separated from an additional battery electrode. In this regard, a spacing element coupled with the circuit board may also couple with the additional battery electrode. The spacing element may include a variety of designs and functions. For example, the spacing element may include a leaf spring design that bends in response to contact with the battery electrode. As another example, the spacing element may include a cantilevered design that also bends in response to contact with the battery electrode. 
     In addition bonding a tab with a battery, the welding operation may be used to bond other components in the electronic device. For example, multiple circuit boards may be coupled with one another by welding together multiple tabs, with each tabs coupled with a circuit board. Alternatively, a circuit board may couple with a housing of the electronic device by welding a tab with the housing. Also, the tabs may include various configurations to maintain the circuit board with the housing. For example, the tab may include a preloaded tab pressed against the housing while the preloaded tab is welded with the housing. Also, a compressible material can be positioned between the circuit board and the housing to provide support to the circuit board as well as provide a force to the circuit board to maintain the circuit board in contact with the tab. 
     These and other embodiments are discussed below with reference to  FIGS. 1-21 . 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  illustrates an isometric view of an embodiment of an electronic device  100 , in accordance with some described embodiments. In some embodiments, the electronic device  100  is a desktop computing device. In other embodiments, the electronic device  100  is a tablet computing device. Still, in other embodiments, the electronic device  100  is a wearable electronic device. In the embodiment shown in  FIG. 1 , the electronic device  100  is a mobile communication device, such as a smartphone. 
     The electronic device  100  may include an enclosure  102 , or housing, that defines an internal cavity to receive several internal components (not shown), such as a circuit board, processor circuit, memory circuit, and an internal power supply, as non-limiting examples. The enclosure  102  may include a metal, such as aluminum or steel, or a metal alloy that includes two or more metals. Alternatively, the enclosure  102  may include a non-metal material (or materials), such as ceramic. 
     The electronic device  100  may further include a display assembly  104  (shown as a dotted line) designed to present visual information, in the form of still images and/or video. The display assembly  104  may include a capacitive touch sensitive layer designed to receive a touch input to alter the visual information. Also, the electronic device  100  may include a protective cover  106  that overlays the display assembly  104 . The protective cover  106  may include a transparent material, such as glass or sapphire, as non-limiting examples. 
     The electronic device  100  may further include a button  108  used a control input to a processor circuit (not shown). For example, the button  108  may depress in response to a force, and provide a control that alters the visual information presented by the display assembly  104 . Also, although not shown, the electronic device  100  may include one or more buttons disposed along the enclosure  102  to provide an additional control input. 
       FIG. 2  illustrates a plan view of the electronic device  100  in  FIG. 1 , showing a substrate  120  and an internal power supply  130 . For purposes of illustration, the display assembly  104  and the protective cover  106  (both shown in  FIG. 1 ) are removed. The substrate  120  may include a circuit board, including a printed circuit board or a flexible circuit board. The internal power supply  130  may include a cell  132  (for example, a battery cell) surrounded by a can  134 . The internal power supply  130  may provide power to various internal components (not shown) of the electronic device  100 . 
     As shown, the substrate  120  is coupled with the internal power supply  130 . For example, as shown in a first enlarged view  180 , the substrate  120  includes a tab  122 . The tab  122  may include a metal, such as aluminum or nickel. Also, the tab  122  can take the form of a plaque suitable for use in a soldering operation. Also, the tab  122  may electrically couple to a first electrical pad  124  disposed on the substrate  120 . Further, a bonding operation, such as soldering operation, may reflow solder (not shown) positioned on the first electrical pad  124  and the tab  122  in order to electrically and mechanically couple the tab  122  with the first electrical pad  124 . 
     As shown, the tab  122  is coupled with a first electrode  136  of the internal power supply  130 , which may include an electrical coupling between the tab  122  and the first electrode  136 . The first electrode  136  is one of two electrodes, or terminals, the internal power supply  130 , with one electrode being positive and one electrode being negative. The tab  122  may be bonded with the first electrode  136  by a welding operation. For example, a laser welding operation that provides thermal energy by a laser beam that passes through an opening (not shown) of the circuit board and contacts the tab  122  to at least partially melt the tab  122  and the first electrode  136 , and form a bond between the tab  122  and the first electrode  136 . This will be shown and described below. 
     In some instances, the tab  122  includes a U-shape or other bent configuration. However, in order to reduce the space or volume occupied by the substrate  120  and the internal power supply  130 , it may be desirable to minimize the size and shape of the tab  122 . In this regard, the tab  122  shown in  FIG. 2  includes a generally flat or planar metal element, and accordingly, minimizes the space between the substrate  120  and the internal power supply  130 , as compared to a U-shaped or bent tab. 
     Further, as shown in a second enlarged view  190 , the internal power supply  130  include a second electrode  138  electrically coupled with a spacing element  126  secured with the substrate  120  by way of a second electrical pad  128  disposed on the substrate  120 . The second electrode  138  may include a negative electrode. However, the location of the first electrode  136  and the second electrode  138  may be reversed in other configurations. The spacing element  126  may include an electrically conductive material, such as a metal, and accordingly, may provide an electrical pathway between the second electrode  138  and the second electrical pad  128 . 
     In some instances, the second electrode  138  is non-coplanar with respect to the first electrode  136 . However, the spacing element  126  provides an additional extension such that the second electrode  138  contacts the spacing element  126 , and the internal power supply  130  remains electrically coupled with the substrate  120  by way of the first electrode  136  and the second electrode  138 . 
     Also, the spacing element  126  shown in  FIG. 2  may include a leaf spring design, allowing the spacing element  126  to flex or bend in response to a force provided by the second electrode  138 , when, for example, the internal power supply  130  moves with respect to the substrate  120 . Also, the spacing element  126  may flex or bend to accommodate some differences in positioning between the substrate  120  and the internal power supply  130 , and in particular, the second electrode  138 . Alternatively, or in combination, the spacing element  126  is designed may accommodate different tolerance (sizes) of the substrate  120  and/or the internal power supply  130 , which may facilitate an assembly operation of the substrate  120  and the internal power supply  130 . While a leaf spring configuration is shown for the spacing element  126 , other configurations are possible, and will be shown below. 
       FIGS. 3-6  show and describe substrates having different electrical pad configurations. The electrical pad configurations shown in  FIGS. 3-6  may be used by any substrate shown and described herein. Also, the electrical pads, in each configuration, or design to receive and electrically couple with a tab or another electrical component. In this regard, the electrical pads may include a material such as gold or copper, and as a result, allow for a bonding operation, such as soldering, to electrically and mechanically couple with the tab or other electrical component. Further, although  FIGS. 3-6  show a single surface of a substrate having electrical pad (or pads) in a particular configuration, an additional surface of the substrate may include an electrical pad (or pads) in a similar configuration as shown for the single surface. 
       FIG. 3  illustrates an isometric view of an alternate embodiment of a substrate  220  having a pair of electrical pads in the form of parallel plates. As shown, the electrical pads include a first electrical pad  222  and a second electrical pad  224  parallel to the first electrical pad  222 . Also, the first electrical pad  222  and the second electrical pad  224  may surround an opening  226 , or through hole, formed in the substrate  220 . The opening  226  may provide a path for a laser welding operation to weld together a tab (now shown) with the first electrical pad  222  and the second electrical pad  224 . Also, the substrate  220  may include a first metal trace  232  and a second metal trace  234  (also referred to as traces) that extend internally along the substrate  220  to electrically couple the first electrical pad  222  and the second electrical pad  224 , respectively, to other component(s) (not shown) of the substrate  220 . 
       FIG. 4  illustrates an isometric view of an alternate embodiment of a substrate  320  having a pair of electrical pads partially surrounding an opening  326  of the substrate  320 . As shown, the electrical pads include a first electrical pad  322  and a second electrical pad  324  that combine to surround the opening  326 . Further, the first electrical pad  322  and the second electrical pad  324  may extend along an outer perimeter of the opening  326  and provide additional surface area (as compared to the pads in  FIG. 3 ) that is used to couple with a component (not shown). Although not labeled, the substrate  320  includes metal traces that electrically connect the first electrical pad  322  and the second electrical pad  324  with another electrical pad and/or an electrical component (not shown) coupled to the substrate  320 . 
       FIG. 5  illustrates an isometric view of an alternate embodiment of a substrate  420  having multiple electrical pads partially surrounding an opening  430  of the substrate  420 . As shown, the electrical pads include a first electrical pad  422 , a second electrical pad  424 , a third electrical pad  426 , and a fourth electrical pad  428  that combine to surround the opening  430 . As shown, the electrical pads extend around an outer perimeter of the opening  430  and provide a bonding location for a component. Further, the electrical pads are broken into multiple segments, which may reduce the amount of material used, as compared to the electrical pads in  FIG. 4 . Although not labeled, the substrate  320  includes metal traces that electrically connect the first electrical pad  422 , the second electrical pad  424 , the third electrical pad  426 , and the fourth electrical pad  428  with another electrical pad and/or an electrical component (not shown) coupled to the substrate  320 . 
       FIG. 6  illustrates an isometric view of an alternate embodiment of a substrate  520  having a single electrical pad surrounding an opening  526  of the substrate  520 . As shown, an electrical pad  522  fully sounds an outer perimeter of the opening  526 , allowing a component (not shown) to couple with the electrical pad  522  in any rotational orientation with respect to the substrate  520 . Although not labeled, the substrate  520  includes metal traces that electrically connect the electrical pad  522  with another electrical pad and/or an electrical component (not shown) coupled to the substrate  520 . 
       FIG. 7  illustrates a cross sectional view of an embodiment of a substrate  620 , showing the substrate  620  undergoing a reflow operation in order to solder components to the substrate  620 , in accordance with some described embodiments. As shown, the substrate  620  includes electrical pads, such as a first electrical pad  622  and a second electrical pad  624  that surround an opening  626  of the substrate  620 . The opening  626  can be characterized as a through hole that extends from a first opening  646  at a first surface  652  of the substrate  620  to a second opening  648  at a second surface  654  of the substrate  620 . 
     As shown, a tab  630  is disposed over the first electrical pad  622  and the second electrical pad  624 . The tab  630  may be positioned over the first opening  646  such that the tab  630  may undergo an additional bonding operation with another component. This will be shown and described below. Although a particular size and number of electrical pads are shown, the electrical pads may vary in size and number. 
     The reflow operation may include a soldering operation that provides heat  644  to a first solder material  632  and a second solder material  634 , thereby bonding the tab  630  with the first electrical pad  622  and the second electrical pad  624 . The heat is sufficient to melt the first solder material  632  and the second solder material  634  such that the tab  630  bonds and electrically couples with the first electrical pad  622  and the second electrical pad  624 . Also, the tab  630  may be positioned over the opening  626 . 
     In addition to the tab  630 , some components, such as integrated circuits or electrical components, can be secured with the substrate  620 . For example, the substrate  620  may include a third pad  628  having a component  640  disposed on the third pad  628 , with the reflow operation melting a third solder material  638  to electrically and mechanically couple the component  640  with the third pad  628 . Also, while a single component, represented by the component  640 , is shown, several additional components may be coupled with the substrate  620  in a manner similar to that of the component  640 . 
       FIG. 8  illustrates a cross sectional view of the substrate  620  shown in  FIG. 7  subsequent to the reflow operation. As shown, the tab  630  and the component  640  are electrically and mechanically coupled with the substrate  620  via the solder materials described above. Also, as shown, both the tab  630  and the component  640  are bonded with a first surface  652  of the substrate  620 . However, the substrate  620  includes a second surface  654 , opposite the first surface, that may also receive a tab (not shown) or another component. In this regard, electrical pads, such as a third electrical pad  656  and a fourth electrical pad  658 , may be positioned on the second surface  654 . The third electrical pad  656  and the fourth electrical pad  658  may include a configuration as that of the first electrical pad  622  and the second electrical pad  624 , respectively. Alternatively, the third electrical pad  656  and the fourth electrical pad  658  may include a different configuration than the first electrical pad  622  and the second electrical pad  624 . Also, in some embodiments (not shown), the first electrical pad  622  and the second electrical pad  624  extend through the substrate  620  such that the first electrical pad  622  and the second electrical pad  624  protrude beyond the substrate  620  at both the first surface  652  and the second surface  654 . Accordingly, in these embodiments, the third electrical pad  656  and the fourth electrical pad  658  are removed. 
       FIG. 9  illustrates a cross sectional view of the substrate  620  secured with the internal power supply, with the tab  630  positioned against an electrode  662  of the internal power supply  660 . Although not shown, a fixture may hold the substrate  620  in place and in a desired location relative to the internal power supply  660 , such that the tab  630  engages the electrode  662 . 
       FIG. 10  illustrates a cross sectional view of the substrate  620  and the internal power supply  660  shown in  FIG. 9 , further showing the tab  630  undergoing a bonding operation to weld the tab  630  with the electrode  662 . As shown, a tool  670  is used to perform the bonding operation. In some embodiments, the tool  670  is a laser welding tool that emits a laser beam  672  to provide heat to weld the tab  630  with the electrode  662 . Further, the tool  670  is positioned such that the laser beam  672  passes through the opening  626  of the substrate  620 . The laser beam  672  may supply sufficient heat to melt the together materials that form the tab  630  and the electrode  662 , which may include nickel and aluminum materials, as an example. Further, the laser beam  672  may be sufficiently tuned or focused such that an outer perimeter of the laser beam  672  supplies relatively less heat, as compared to a central area of the laser beam  672 , to avoid damage to the substrate  620 . 
       FIG. 11  illustrates a cross sectional view of the substrate  620  and the internal power supply  660  shown in  FIG. 10 , showing the tab  630  welded with the electrode  662 . As shown, the tab  630  is bonded with the electrode by a weld  664  between the tab  630  and the electrode  662 , and accordingly, the substrate  620  is secured with the internal power supply  660 . By locating the substrate  620  in a desired location relative to the internal power supply  660  and then welding the tab  630  (as shown in  FIG. 10 ), the substrate  620  is welded and secured with the internal power supply  660 , and need not be repositioned by another process or processes. Accordingly, the process shown in  FIG. 11  eliminates the need for a bendable tab. Also, as the tab  630  is generally flat or planar, the space occupied by the tab  630  is minimized, thereby reducing the overall space occupied by the substrate  620  and the internal power supply  660 , as the substrate  620  can be positioned closer to the internal power supply  660 , as opposed to using a bent or folded tab. Also, it should be noted that the location of the weld  664  corresponds to the location of the opening  626 , as the welding operation is performed through the opening. 
     Also, the welding operation is possible in part by the opening  626  and the location of the tab  630  relative to the opening  626 . In other words, the opening  626  provides access to the tab  630  for a welding operation (shown in  FIG. 10 ) such that the substrate  620  can be positioned in accordance with a desired manner and need not be repositioned after the welding operation. This reduces manufacturing times and eliminates misalignment of the substrate  620 . 
     In some instances, the substrate  620  is limited in size. In this regard, both surfaces of the substrate  620  may be configured to receive components. For example,  FIG. 12  illustrates an isometric view of the substrate  620  and the internal power supply  660  shown in  FIG. 11 , further showing a component  680  secured with the substrate  620  on an opposing surface of the substrate  620 . The component  680  may include an electrical component, such as a processing circuit, as a non-limiting example. As shown, the component  680  is located on the second surface  654  of the substrate  620 , with the tab  630  is located on the first surface  652  (labeled in  FIG. 8 ). Further, the component  680  may electrically couple with the third electrical pad  656  and the fourth electrical pad  658 . This may include an additional bonding operation that includes soldering the component  680  with the third electrical pad  656  and the fourth electrical pad  658  using solder material (not shown). Moreover, to further utilize limited space on the second surface  654 , the component  680  may be positioned over the second opening  648 , as shown in  FIG. 12 . 
       FIG. 13  illustrates a partial cross sectional view of an alternate embodiment of a substrate  720  secured with an internal power supply  760  by a tab  1130 . The substrate  720  may include a circuit board. As shown, the tab  1130  is electrically and mechanically coupled with an electrode  762  of the internal power supply  760  by a weld  764 . The weld  764  may be performed by a welding operation in a manner previously described. As shown in the enlarged view, the substrate  720  may include stepped profile such that the tab  730  is co-planar, or flush, with respect to a surface  754  of the substrate  720 . Inn some embodiments (not shown), the stepped profile of the substrate  720  includes size and shape such that the tab  730  is non-coplanar, or sub-flush, with respect to the surface  754 . 
     In addition to bonding a tab with an electrode, the welding operation described herein may bond together different components. For example,  FIG. 14  illustrates a cross sectional view of a first substrate  820  secured with a second substrate  920  by a pair of tabs welded together. The first substrate  820  and the second substrate  920  may include a first circuit board and a second circuit board, respectively. As shown, the first substrate  820  may include a first opening  826  that receives a first tab  830 , and the second substrate  920  may include a second opening  926  that receives a second tab  030 . A tool, such as the tool  670  (shown in  FIG. 10 ), may provide a laser welding operation to a weld  864  between the first tab  830  and the second tab  930 , thereby securing the first substrate  820  with the second substrate  920 . Further, when the substrates are circuit boards, the bond between the first tab  830  and the second tab  930  may represent a board-to-board connection. 
       FIG. 15  illustrates a cross sectional view of an embodiment of a tab  1030  used to secure a substrate  1020  with a housing  1002 . The housing  1002  may include a housing or enclosure of an electronic device, such as the enclosure  102  and electronic device  100  (shown in  FIG. 1 ). As shown, prior to bonding with the housing  1002 , the tab  1030  is configuration a preloaded arrangement, similar to a preloaded or compressed arrangement of a spring. 
       FIG. 16  illustrates a cross sectional view of the tab  1030  shown in  FIG. 15 , showing the tab  1030  pressed against the housing  1002  and undergoing a welding operation to weld the tab  1030  with the housing  1002 . As shown, an object  1050 , such as a rod, may press against the tab  1030  such that the tab  1030  lies flat against the housing  1002 . Then, a tool  1070  is used to perform the bonding operation. In some embodiments, the tool  1070  is a laser welding tool that emits a laser beam  1072  to provide heat to weld the tab  1030  with the housing  1002 , thereby forming a weld  1064  between the tab  1030  and housing  1002 . Although not shown, subsequent to the bonding operation, when the object  1050  is removed, the tab  1030  remains flat against the housing  1002 . In other words, the tab  1030  is no longer in the preloaded arrangement. In this regard, the tab  1030  may provide a force to the substrate  1020  causing the substrate  1020  to remain engaged with the housing  1002 . 
       FIG. 17  illustrates a cross sectional view of an embodiment of a tab  1130  used to secure a substrate  1120  with a housing  1102 , further showing a compressible material  1140  positioned between the substrate  1120  and the housing  1102 . The compressible material  1140  may include a compressible foam or compressible adhesive, as non-limiting examples. As shown, the tab  1130  is secured with the housing  1102  by weld  1164  formed from a welding operation in a manner previously described. In this configuration, the compressible material  1140  may provide a cushion for the substrate  1120  against a force to the housing  1102 . Further, when the tab  1130  secures the substrate  1120  with the housing  1102 , the compressible material  1140  may provide a force to the substrate  1120  causing the substrate  1120  to remain engaged with the tab  1130 . 
     Returning to  FIG. 2 , the spacing element  126  may span the distance between the second electrical pad  128  and the second electrode  138  to electrically couple the second electrical pad  128  with the second electrode  138 . As shown in  FIG. 2 , the spacing element  126  includes a leaf spring designed to bend or flex in response to a force to the spacing element  126 . However, other configurations of a spacing element are possible. 
     For example,  FIGS. 18-20  show different configuration of a spacing element that may be used to electrically an electrode when an electrical pad. The spacing elements shown in  FIGS. 18-20  may include an electrically conductive material, such as a metal. Also, the spacing element  126  (shown in  FIG. 2 ) may be substituted for any spacing element shown in  FIGS. 18-20 . 
       FIG. 18  illustrates an isometric view of an embodiment of a spacing element  1226  having a dome configuration. The spacing element  1226  may include a base portion  1228  and a dome portion  1230  extending from the base portion  1228 . In some embodiments, the base portion  1228  couples with an electrical pad (not shown), while the dome portion  1230  extends to engage an electrode (not shown). However, the configuration of the base portion  1228  and the dome portion  1230  may switch. 
       FIG. 19  illustrates an isometric view of an alternate embodiment of a spacing element  1326  having a cross configuration. The spacing element  1326  may include a base portion  1328  and an elevated portion  1330  extending from the base portion  1328 . In some embodiments, the base portion  1328  couples with an electrical pad (not shown), while the elevated portion  1330  extends to engage an electrode (not shown). However, the configuration of the base portion  1328  and the elevated portion  1330  may switch. Also, the spacing element  1326  may bend or flex in response to a force. For example, a force provided to the elevated portion  1330  may compress, or reduce the height of, the spacing element  1326 . This may be caused in part by a force from an electrode (not shown). Also, the flexible property of the spacing element  1326  may accommodate different tolerances in the components used, such as a substrate and/or an internal power supply. 
       FIG. 20  illustrates an isometric view of an alternate embodiment of a spacing element  1426  having a cantilevered configuration. The spacing element  1426  may include a base portion  1328  and a flexible portion  1430  extending from the base portion  1428 . In some embodiments, the base portion  1428  couples with an electrical pad (not shown), while the flexible portion  1430  extends to engage an electrode (not shown). However, the configuration of the base portion  1428  and the flexible portion  1430  may switch. In either event, when the spacing element  1426  includes a cantilevered configuration, only the base portion  1428  is attached to an object. Also, the spacing element  1426  may bend or flex in response to a force. For example, a force provided to the flexible portion  1430  may compress, or reduce the height of, the spacing element  1326 . This may be caused in part by a force from an electrode (not shown). Also, the flexible property of the spacing element  1426  may accommodate different tolerances in the components used, such as a substrate and/or an internal power supply. 
       FIG. 21  illustrates a flowchart  1500  showing a method for assembling a circuit board with an internal component of an electronic device. The circuit board may include an opening and an electrical pad that at least partially surrounds the opening. The internal component may include an internal power supply that provides electrical current to several operational components in the electronic device. Also, the substrate may include a circuit board that carries at least some of the operational components, and is also in communication with the internal component. 
     In step  1502 , a tab engages with the electrical pad and the internal component. The tab may include a flat or planar configuration. Also, the tab may include an electrically conductive material, such as a metal. In order to properly engage the tab with the internal component, a fixture may be used to align the substrate with the internal component. 
     In step  1504 , thermal energy is provided through the opening to weld the tab with the component. A tool may provide the thermal energy. The tool may include a welding tool. Further, the welding tool may include a laser welding tool that emits a laser beam. The laser beam may provide sufficient heat to form a weld between the tab and the internal component. In some embodiments, the internal component includes an electrode. In this manner, the weld may bond the tab with the electrode. 
     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 the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the 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: 20170113
Publication Date: 20180724
Grant Date: 20180724
Priority Date: 20160824
Inventors: WERLEY, CHARLES W.
BALARAM, HARAN
WINSLOW, RICHARD L.
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K1/113", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/10545", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/0397", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10265", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/181", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/113", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2203/107", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/1028", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10037", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/0397", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/328", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/0394", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/09072", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10515", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/0394", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/107", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/328", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/0397", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/328", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/181", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2203/107", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/113", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/0394", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10265", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/1028", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10037", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10515", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10545", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/09072", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 61244225