PATENT DOCUMENT

Publication Number: US-9001522-B2
Application Number: US-201213674834-A
Country: US
Kind Code: B2

Title: Printed circuits with staggered contact pads and compact component mounting arrangements

Abstract:
Electronic devices may be provided with printed circuits to which integrated circuits and other electrical components may be mounted. A first printed circuit may have a first surface with an array of contact pads arranged in rows and columns. Each column of contact pads may have a series of contact pads separated by gaps. The contact pads in each column may be staggered with respect to the contact pads in adjacent columns such that each contact pad in a given column is horizontally adjacent to associated gaps in the adjacent columns. A component may be mounted to an opposing surface of the printed circuit such that it overlaps one of the gaps between the staggered contact pads. By mounting the component to portions of the first printed circuit that do not overlap the staggered contact pads, the risk of damaging the electrical component during solder reflow operations may be minimized.

Claims:
What is claimed is: 
     
       1. Apparatus, comprising:
 a printed circuit having first and second opposing surfaces, wherein the first surface includes a plurality of contact pads arranged in a two-dimensional array having rows and columns, wherein each column of contact pads contains a plurality of contact pads separated by respective gaps, and wherein the contact pads in each column are staggered with respect to the contact pads in adjacent columns; 
 at least one electrical component mounted to the second surface, wherein the at least one electrical component overlaps one of the gaps and does not directly overlap any of the contact pads; 
 an additional printed circuit; and 
 solder connections between the additional printed circuit and at least one contact pad in the plurality of contact pads, wherein the additional printed circuit comprises a flexible printed circuit. 
 
     
     
       2. The apparatus defined in  claim 1  wherein the contact pads in each column are staggered with respect to the contact pads in adjacent columns such that each contact pad in a given column is horizontally adjacent to associated gaps in the adjacent columns. 
     
     
       3. The apparatus defined in  claim 1  wherein the solder connections comprise hot bar solder connections. 
     
     
       4. The apparatus defined in  claim 1  wherein the electrical component is mounted to the second surface using solder. 
     
     
       5. The apparatus defined in  claim 1  wherein the printed circuit comprises a flexible printed circuit. 
     
     
       6. A method, comprising:
 receiving a first printed circuit having a surface with a plurality of contact pads, wherein the surface includes a plurality of contact pads arranged in a two-dimensional array having rows and columns, wherein each column of contact pads contains a plurality of contact pads separated by respective gaps, and wherein the contact pads in each column are staggered with respect to the contact pads in adjacent columns; 
 mounting at least one component to a region on an opposing surface of the first printed circuit, wherein the region overlaps a respective one of the gaps and does not directly overlap any of the contact pads; and 
 applying heat and pressure to a second printed circuit to form solder connections between contact pads on the second printed circuit and the contact pads on the first printed circuit, wherein the second printed circuit comprises a flexible printed circuit. 
 
     
     
       7. The method defined in  claim 6  further comprising:
 aligning the contact pads on the second printed circuit with the contact pads on the first printed circuit prior to applying the heat and pressure. 
 
     
     
       8. The method defined in  claim 6  wherein applying the heat and pressure to the second printed circuit comprises pressing the second printed circuit against the first printed circuit with a hot bar to form hot bar solder connections. 
     
     
       9. The method defined in  claim 6  wherein mounting the at least one component to the opposing surface comprises forming a solder connection between the at least one component and the first printed circuit. 
     
     
       10. Apparatus, comprising:
 a printed circuit substrate having first and second opposing surfaces, wherein the first surface comprises a plurality of staggered contact pads separated by gaps, wherein the plurality of staggered contact pads is arranged in a two-dimensional non-rectangular lattice, wherein the plurality of staggered contact pads comprises first, second, and third rows of contact pads, wherein each row has at least two contact pads separated from each other by a first distance, wherein first and third rows are laterally aligned with each other, and wherein the second row is interposed between the first and third rows and is offset from each of the first and third rows by a distance less than the first distance; 
 a component mounted to the second surface, wherein the component overlaps only a respective one of the gaps; and 
 an external circuit electrically coupled to first and second contact pads in the plurality of staggered contact pads via hot bar solder connections. 
 
     
     
       11. The apparatus defined in  claim 10  wherein the respective one of the gaps is interposed between the first and second contact pads. 
     
     
       12. The apparatus defined in  claim 10  wherein the external circuit comprises a flexible printed circuit substrate. 
     
     
       13. The apparatus defined in  claim 10  wherein the printed circuit substrate comprises a flexible printed circuit substrate. 
     
     
       14. The apparatus defined in  claim 10  wherein the printed circuit substrate comprises a rigid printed circuit substrate. 
     
     
       15. The apparatus defined in  claim 10  wherein the component comprises an integrated circuit. 
     
     
       16. The apparatus defined in  claim 10  further comprising solder connections configured to mechanically and electrically couple the component to the second surface of the printed circuit substrate.

Description:
This application claims the benefit of provisional patent application No. 61/560,035, filed Nov. 15, 2011, which is hereby incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     This relates to electronic devices and, more particularly, to mounting components to printed circuits in electronic devices. 
     Electronic devices such as cellular telephones and other devices include components that are mounted on printed circuits. Solder connections are often used to mount components to a printed circuit. Solder connections are also sometimes used to connect printed circuits to each other. 
     Pressure and heat are often used during solder operations to form a reliable solder connection. If care is not taken, the pressure and heat involved in forming a solder connection on a printed circuit can damage components mounted to the printed circuit. Conventional printed circuits often include unutilized space devoid of components in order to avoid damaging the components during solder reflow operations. This type of arrangement reduces the component density of the printed circuit, which in turn can lead to an undesirable increase in the size of an electronic device. 
     It would therefore be desirable to be able to provide improved ways of mounting electronic components and other structures to printed circuits. 
     SUMMARY 
     Electronic devices may be provided with printed circuits to which integrated circuits and other electrical components may be mounted. 
     A first printed circuit may have a first surface with an array of contact pads arranged in rows and columns. Each column of contact pads may have a series of contact pads separated by gaps. The contact pads in each column may be staggered with respect to the contact pads in adjacent columns such that each contact pad in a given column is horizontally adjacent to associated gaps in the adjacent columns. This type of staggered array may be referred to as a two-dimensional non-rectangular lattice pattern. 
     One or more components may be mounted to an opposing surface of the printed circuit. The components may be mounted in component mounting regions. Each component mounting region may overlap an associated gap on the opposing surface that separates the staggered contact pads. 
     A second printed circuit may be mechanically and electrically coupled to the first printed circuit using solder. Solder paste may be interposed between contacts on the second printed circuit and the staggered contacts on the first printed circuit. A hot bar tool may be used to press the second printed circuit against the first printed circuit during solder reflow operations. The heat and pressure provided by the hot bar tool may convert the solder paste into solder connections. 
     By mounting the component to portions of the first printed circuit that do not overlap the staggered contact pads, the risk of damaging the electrical component during solder reflow operations may be minimized. 
     Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of an illustrative electronic device of the type that may be provided with printed circuit structures in accordance with an embodiment of the present invention. 
         FIG. 2  is a perspective view of a conventional printed circuit having laterally aligned rows of contact pads and a surface devoid of components. 
         FIG. 3  is a top view of an illustrative printed circuit having an array of staggered contact pads in accordance with an embodiment of the present invention. 
         FIG. 4  is a cross-sectional side view of an illustrative printed circuit arrangement in which components and printed circuit structures are attached to a printed circuit using solder in accordance with an embodiment of the present invention. 
         FIG. 5  is a flow chart of illustrative steps involved in mounting components and printed circuit structures to a printed circuit using solder in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic devices may be provided with printed circuits to which integrated circuits and other electrical components may be mounted. For example, components may be mounted to printed circuits such as rigid printed circuit boards (e.g., fiberglass-filled epoxy boards) and flexible printed circuits (e.g., sheets of polyimide or flexible layers of other polymers). Connectors such as board-to-board connectors and other connectors with mating contacts may be used to couple printed circuits together. Conductive adhesive and direct solder connections may also be used in forming electrical connections between printed circuits. As an example, printed circuits may be soldered together using hot bar soldering techniques in which a heated tool (a hot bar) is brought into proximity of patterned solder paste on a printed circuit. As the solder paste is heated and reflows, hot bar solder joints may be formed to electrically and mechanically couple the printed circuits together. 
     An illustrative electronic device of the type that may be provided with printed circuits having electrical connections such as hot bar solder connections is shown in  FIG. 1 . Device  10  of  FIG. 1  may be a handheld device such as a cellular telephone or media player, a tablet computer, a notebook computer, other portable computing equipment, a wearable or miniature device such as a wristwatch or pendant device, a television, a computer monitor, or other electronic equipment. 
     As shown in  FIG. 1 , electronic device  10  may include a display such as display  14 . Display  14  may be a touch screen that incorporates a layer of conductive capacitive touch sensor electrodes or other touch sensor components or may be a display that is not touch-sensitive. Display  14  may include an array of display pixels formed from liquid crystal display (LCD) components, an array of display pixels formed from light-emitting diode (OLED) components, an array of electrophoretic display pixels, an array of electrowetting display pixels, or display pixels based on other display technologies. 
     Display  14  may be protected using a display cover layer such as a layer of transparent glass or clear plastic. Openings may be formed in the display cover layer. For example, an opening may be formed in the display cover layer to accommodate a button such as button  16  and, if desired an opening may be used to form a speaker port. Device configurations without openings in display  14  may also be used for device  10 . 
     Device  10  may have a housing such as housing  12 . Housing  12 , which may sometimes be referred to as an enclosure or case, may be formed of plastic, glass, ceramics, fiber composites, metal (e.g., stainless steel, aluminum, etc.), other suitable materials, or a combination of any two or more of these materials. 
     Housing  12  may be formed using a unibody configuration in which some or all of housing  12  is machined or molded as a single structure or may be formed using multiple structures (e.g., an internal frame structure, one or more structures that form exterior housing surfaces, etc.). 
     Device  10  may include printed circuits to which integrated circuits and other electrical components are mounted. Solder connections may be used in attaching components to printed circuits and in attaching printed circuits to each other. For example, hot bar solder connections may be used in directly attaching printed circuits to each other without requiring a separate connector. 
     To form solder connections, solder paste may be printed onto contact pads on a printed circuit substrate. A surface mount tool such as a pick and place tool may be used to position components on the printed solder paste. Following placement of the components on the printed circuit substrate, solder connections may be formed by reflowing solder paste structures in a reflow oven, by heating solder paste or solder balls using a localized heat source such as a hot bar or heat gun, or using other suitable solder reflow techniques. 
     In conventional printed circuit arrangements, the heat and pressure applied during solder reflow operations prohibits components from being mounted to certain portions of the printed circuit.  FIG. 2  is a perspective view of a conventional printed circuit  18  having unutilized portions that are devoid of components. 
     As shown in  FIG. 2 , printed circuit  18  includes laterally aligned rows of contact pads  20  on upper surface  18 U of printed circuit substrate  18 . During solder reflow operations, hot bar tool  22  is used to heat solder paste on contact pads  20  to form solder connections between contact pads  20  and electrical components. The heat and pressure that are applied to contact pads  20  in direction  24  during solder reflow operations can damage components attached to lower surface  18 L of printed circuit  18 . For example, a component mounted on lower surface  18 L that overlaps contact pad  20  can be damaged by the heat and pressure that translates though the thickness of substrate  18  from contact pad  20  during reflow operations. 
     In order to avoid damaging components during solder reflow operations, lower surface  18 L of substrate  18  includes unutilized portions that are devoid of components. Conventional printed circuit arrangements of the type shown in  FIG. 2  may therefore suffer from reduced component density, which can in turn lead to an overall increase in the size of the electronic device in which printed circuit  18  is mounted. 
       FIG. 3  is a top view of an illustrative printed circuit arrangement in which a printed circuit substrate such as printed circuit substrate  26  includes an efficient arrangement of contact pads such as contact pads  28 . A contact pad arrangement of the type shown in  FIG. 3  may maximize the amount of surface area on substrate  26  available for mounting components, thereby allowing for a more compact component mounting arrangement in device  10 . 
     Printed circuit substrate  26  may include one or more layers of dielectric and one or more layers of conductor. Printed circuit  26  may, for example, be a flexible printed circuit formed from materials such as polyimide (sometimes referred to as a “flex circuit”), may be a rigid printed circuit board formed from a material such as fiberglass-filled epoxy (e.g., FR4), or may be formed from other suitable materials or combinations of these materials. If desired, printed circuit  26  may be a “rigid-flex” printed circuit that includes both rigid and flexible layers. 
     Printed circuit  26  may include one or more conductive pads such as contact pads  28  formed on top surface  26 T of printed circuit  26 . Although surfaces of substrates may sometimes be referred to as “top” and “bottom” surfaces or “upper” and “lower” surfaces, it should be understood that a substrate such as substrate  26  may be mounted in any suitable orientation in device  10 . 
     Contact pads  28  may be formed from conductive material such as tin, lead, gold plated copper, or other suitable materials. Integrated circuits and other electrical components such as additional printed circuits may, if desired, be electrically and mechanically coupled to printed circuit  26  via contact pads  28 . 
     As shown in  FIG. 3 , contact pads  28  may be arranged on top surface  26 T of substrate  26  in a two-dimensional array of rows and columns. Contact pads  28  may, for example, be spaced a distance D 1  apart from each other. For simplicity, only a portion of substrate  26  is shown in  FIG. 3 . If desired, there may be a greater or fewer number of contact pads  28  on substrate  26  than the number of contacts  28  shown in  FIG. 3 . The example of  FIG. 3  is merely illustrative. 
     The rows and columns of contact pads  28  on surface  28 T of substrate  28  may be staggered with respect to one another. For example, row  1  and row  3  of contact pads  28  may be laterally aligned with each other, whereas row  2  interposed between rows  1  and  3  may be shifted with respect to rows  1  and  3  by a distance D 2 . Distance D 2  by which row  2  is offset from row  1  may be less than distance D 1 . This type of staggered array may be referred to as a two-dimensional non-rectangular lattice pattern. 
     The example of  FIG. 3  in which contact pads  28  are spaced a distance D 1  apart from each other is merely illustrative. If desired, there may be different distances between different pairs of contacts. For example, a first region of contacts may have a first bond pad pitch, and a second region of contacts may have a second bond pad pitch that is different from the first bond pad pitch (if desired). In general, any suitable distance may separate a given pair of contact pads  28 . 
     If desired, there may be portions of substrate  26  that are do not include staggered contacts. For example, substrate  26  may include portions in which two or more rows of contacts  28  are laterally aligned with each other in a rectangular grid-like fashion and may include portions in which two or more rows of contacts are staggered in a similar fashion to that of rows  1 ,  2 , and  3  of  FIG. 3 . Printed circuit  26  may include portions without contacts  28 . The example of  FIG. 3  in which substrate  26  includes at least three rows that are staggered with respect to each other is merely illustrative. 
     By staggering rows of contacts  28  on substrate  26 , gaps such as gaps  30  may be created between contacts  28 . The presence of gaps  30  between staggered contacts  28  may allow components to be mounted to an opposing surface of substrate  26  (e.g., a surface of substrate  26  that opposes top surface  26 T). For example, by shifting row  2  of contact pads such that region  30  is free of a contact pad, region  30  may experience reduced amounts of heat and pressure during solder reflow operations. Components may therefore be mounted to an opposing surface of substrate  26  in regions that overlap gaps  30  between staggered contacts  28 . 
     A cross-sectional side view of printed circuit substrate  26  of  FIG. 3  taken along line  32  of  FIG. 3  is shown in  FIG. 4 . As shown in  FIG. 4 , a component such as component  40  may be mounted to lower surface  26 B of substrate  26 . Component  40  may, for example, be an integrated circuit or other electrical component. Component  40  may overlap gap  30  between staggered contact pads  28 . 
     Components such as component  40  may be mounted to conductive pads on printed circuit  26  such as contact pads  44 . Component  40  may have corresponding conductive pads such as contact pads  42  that are configured to align with contact pads  44  on substrate  26 . Contact pads  42  and  44  may be formed from conductive material such as tin, lead, gold plated copper, or other suitable metals. 
     Prior to mounting components such as component  40  to printed circuit substrate  26 , solder paste  46  may be applied to the surface of solder pads  44  on substrate  26  using a solder paste printing stencil. A pick and place tool may then be used to place component  40  on substrate  26  such that contact pads  42  on component  40  align with contact pads  44  on substrate  26 . Solder connections may be formed between component  40  and solder pads  44  by reflowing solder paste structures  46  in a reflow oven, by heating solder paste or solder balls using a localized heat source such as a hot bar or heat gun, or using other suitable reflow techniques. 
     Other electrical components such as additional printed circuit substrates may be coupled to printed circuit substrate  26 . For example, as shown in  FIG. 4 , an additional printed circuit such as printed circuit  34  may be coupled to printed circuit  26  using hot bar solder connections. Printed circuit  34  may, for example, be a flexible printed circuit formed from materials such as polyimide (sometimes referred to as a “flex circuit”), may be a rigid printed circuit board formed from a material such as fiberglass-filled epoxy (e.g., FR4), or may be formed from other suitable materials or combinations of these materials. If desired, printed circuit  34  may be a “rigid-flex” printed circuit that includes both rigid and flexible layers. 
     Printed circuits  26  and  34  may have signal paths such as vias and patterned horizontal lines that are formed from conductive materials such as metal. For example, printed circuit  34  may have solder pads  38  and other metal traces  52 . Printed circuit  26  may have solder pads  28  and other metal traces  54 . If desired, integrated circuits and other electrical components such as components  40  may be electrically coupled to metal traces  54  in substrate  26  and/or metal traces  52  in substrate  34 . Printed circuits  26  and  34  may also be connected to additional printed circuit substrates (e.g., using solder, conductive adhesive, or connectors). 
     Solder  36  may be used to form an electrical connection (i.e., a solder joint) between traces  52  of substrate  34  and traces  54  of substrate  26 . Initially, solder paste may be patterned onto solder pads  28  on upper surface  26 T of substrate  26 . Printed circuit  34  may then be placed in the position shown in  FIG. 4  (e.g., using a computer-controlled positioner). With printed circuit  34  in position, a heating element such as hot bar tool  48  may be pressed down onto substrate  34  in direction  50 . Hot bar  48  may apply heat and pressure to regions  56  on substrate  34  to thereby reflow the solder paste and form a solder joint  36  between contact pads  38  of substrate  34  and contact pads  28  of substrate  26 . 
     Region  30  of substrate  26  between staggered contact pads  28  may experience reduced pressure and heat during solder reflow operations relative to regions  56 . Mounting component  40  to opposing surface  26 B of substrate  26  such that it overlaps gap  30  may therefore minimize the risk of damaging component  40  during solder reflow operations. 
     The staggered arrangement of contacts  28  on upper surface  26 T of substrate  26  allows for components  40  to be mounted to lower surface  26 B, thereby increasing the component capacity of printed circuit substrate  26 . For simplicity, only one component  40  is shown in  FIG. 4  as being mounted to lower surface  26 B of substrate  26 . This is merely illustrative. If desired, there may be multiple gaps  30  between staggered contacts  28 , thereby allowing multiple components  40  to be mounted to portions of lower surface  26 B of substrate  26  that overlap gaps  30 . 
       FIG. 5  is a flow chart of illustrative steps involved in mounting components and printed circuit structures to a printed circuit of the type shown in  FIGS. 3 and 4 . 
     At step  100 , a first printed circuit such as printed circuit  26  having staggered contact pads such as staggered contact pads  28  may be received. The contact pads may, for example, be arranged in an array of rows and columns. Each row may include a series of contact pads spaced a distance D 1  apart from each other (if desired). The rows may include an offset row interposed between first and second aligned rows. The aligned rows may be laterally aligned with each other. The offset row may be shifted with respect to the first and second aligned rows by a distance less than distance D 1 . Shifting the offset row with respect to the first and second aligned rows may provide one or more gaps between the first and second aligned rows. If desired, printed circuit substrate  26  may include multiple rows of staggered contacts and multiple gaps between the staggered contacts. 
     At step  102 , one or more components such as component  40  of  FIG. 4  may be mounted to the opposing surface of substrate  26  (e.g., the surface that opposes the surface on which contact pads  28  are located). Each component may be mounted such that it overlaps an associated gap between a pair of staggered contacts on the opposing surface of the printed circuit substrate. By aligning the components on one surface of the substrate with the gaps on the opposing surface of the substrate, the risk of damaging the components during solder reflow operations may be minimized. 
     At step  104 , a second printed circuit such as printed circuit  34  of  FIG. 4  may be positioned onto first printed circuit  26  such that the contact pads on the second printed circuit align with the staggered contact pads on the first printed circuit. Prior to positioning the second printed circuit onto the first printed circuit, solder paste such as solder paste  36  of  FIG. 4  may be applied to the solder pads on the first printed circuit. If desired, a computer-controlled positioner or other positioning equipment may be used in positioning the second printed circuit onto the first printed circuit. 
     At step  106 , solder reflow operations may be performed to form solder connections (i.e., solder joints) between the staggered contact pads on the first printed circuit and the contact pads on the second printed circuit. This may include, for example, pressing the second substrate against the first substrate with a heated element such as hot bar  48  of  FIG. 4 . The heat and pressure provided by the hot bar tool may reflow the solder between the first and second substrates and may thereby mechanically and electrically couple the second substrate to the first substrate. 
     If desired, other techniques may be used to reflow solder between the first and second substrates (e.g., conveying the substrates into a reflow oven, using other types of localized heat sources such as a heat gun, using other suitable reflow techniques, etc.). The use of a hot bar tool to form solder connections during step  106  is merely illustrative. 
     Areas of the first substrate that are free of contact pads may experience reduced heat and pressure during solder reflow operations relative to areas with contact pads. The risk of damaging components mounted to the first substrate may therefore be minimized because the components do not overlap contact pads to which heat and pressure is applied during solder reflow operations. 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20121112
Publication Date: 20150407
Grant Date: 20150407
Priority Date: 20111115
Inventors: CHEN WYEMAN
NIKKHOO MICHAEL
SALEHI AMIR
Assignee: APPLE INC
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Family ID: 48281059