Method for connecting printed circuit boards and connected printed circuit boards

• US 20030079341A1
• Filed: 10/31/2002
• Published: 05/01/2003
• Est. Priority Date: 10/31/2001
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Miyazaki, Mitsutoshi, Miyagawa, Hiroki, Maeda, Hiroaki, Miyake, Toshihiro, Deguchi, Kazuyuki, Totani, Makoto, Higashida, Akinari, Yazaki, Yoshitaro
• Granted Patent: US 7,080,445 B2
• Time in Patent Office: Days
• US Class Current: 29/830
• CPC Class Codes: H05K 2201/0129 Thermoplastic polymer, e.g. auto-adhesive layer; Shaping of thermoplastic polymer
• CPC Class Codes: H05K 2201/0191 wherein the thickness of the dielectric plays an important role
• CPC Class Codes: H05K 2201/0382 Continuously deformed conductors
• CPC Class Codes: H05K 2201/091 Locally and permanently deformed areas including dielectric material
• CPC Class Codes: H05K 2201/10772 Leads of a surface mounted component bent for providing a gap between the lead and the pad during soldering
• CPC Class Codes: H05K 2201/2009 Reinforced areas, e.g. for a specific part of a flexible printed circuit
• CPC Class Codes: H05K 2203/0108 Male die used for patterning, punching or transferring
• CPC Class Codes: H05K 2203/0195 Tool for a process not provided for in H05K3/00, e.g. tool for handling objects using suction, for deforming objects, for applying local pressure
• CPC Class Codes: H05K 2203/0278 Flat pressure, e.g. for connecting terminals with anisotropic conductive adhesive
• CPC Class Codes: H05K 2203/065 Binding insulating layers without adhesive, e.g. by local heating or welding, before lamination of the whole PCB
• CPC Class Codes: H05K 3/363 by soldering
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/49128 Assembling formed circuit to base
• CPC Class Codes: Y10T 29/49144 by metal fusion
• CPC Class Codes: Y10T 29/49149 by metal fusion bonding

Abstract

A first printed circuit board includes a first insulating board substantially made of thermoplastic resin and a first conductive pattern. A second printed circuit board includes a second insulating board and a second conductive pattern. The first and second printed circuit boards are overlapped. The overlapped portion of the first and second printed circuit boards is heat pressed to connect the first and second printed circuit boards with a heat-pressing tool while the first insulating board is cooled at an area adjacent to an area pressed by the heat-pressing tool. With the heat pressing, the first and second lands are electrically connected and the thermoplastic resin is softened and plastically deformed to bond the first insulating board to the second insulating board. The thickness of the first insulating board is preferably controlled at the heat pressed area and the area adjacent to the heat pressed area by the cooling.

Claims

1. A method for connecting a pair of printed circuit board comprising steps of:

preparing a first printed circuit board by forming a first conductive pattern, which includes a first land, on a first insulating board substantially made of thermoplastic resin;

preparing a second printed circuit board by forming a second conductive pattern, which includes a second land, on a second insulating board;

forming a solder on one of the first and second lands;

overlapping the first and second printed circuit boards such that the first and second lands confront each other;

heat pressing an overlapped portion of the first and second printed circuit boards with a heat-pressing tool at a temperature higher than the glass transition temperature of the thermoplastic resin while the first insulating board is cooled at an area adjacent to an area pressed by the heat-pressing tool to permit the thickness of the first insulating board to change gradually in the cooled area, wherein the first and second lands are electrically connected with the solder and the thermoplastic resin is softened and plastically deformed to bond the first insulating board to the second insulating board at the step of heat pressing.

2. The method in claim 1, wherein a plurality of the first conductive patterns that are substantially parallel to each other in the longitudinal direction of the first printed circuit board are formed at the step of preparing the first printed circuit board, and wherein the method further comprises a step of forming a protective film to cover the first conductive patterns such that the first insulating board is exposed between two of the first conductive patterns, which are adjacent to each other, in the area pressed by the heat-pressing tool.

3. The method in claim 2, wherein a plurality of the second conductive patterns that are substantially parallel to each other in the longitudinal direction of the second printed circuit board are formed at the step of preparing the second printed circuit board such that each second land of the second conductive patterns has a predetermined distance from an end of the second printed circuit board, and wherein the second insulating board is bonded to the first insulating board between two of the first conductive patterns in the predetermined distance.

4. The method in claim 1, wherein a cooling member is placed on the first insulating board at the area adjacent to the area pressed by the heat-pressing tool before the step of heat pressing, and wherein the cooling member is kept in contact with the first insulating board to cool the area adjacent to the area pressed by the heat-pressing tool during the step of heat pressing.

5. A method for connecting a pair of printed circuit board comprising steps of:

preparing a first printed circuit board by forming a first conductive pattern, which includes a first land, on a first insulating board substantially made of thermoplastic resin;

preparing a second printed circuit board by forming a second conductive pattern, which includes a second land, on a second insulating board;

forming a solder on one of the first and second lands;

overlapping the first and second printed circuit boards such that the first and second lands confront each other;

heat pressing an overlapped portion of the first and second printed circuit boards with a heat-pressing tool having a plurality of projections at a temperature higher than the glass transition temperature of the thermoplastic resin such that the thickness of the first insulating board is smaller at areas pressed by the projections than the maximum thickness of the first insulating board at areas between the areas pressed by the projections, wherein the first and second lands are electrically connected with the solder and the thermoplastic resin is softened and plastically deformed to bond the first insulating board to the second insulating board at the step of heat pressing.

6. The method in claim 5, wherein a plurality of the first conductive patterns that are substantially parallel to each other in the longitudinal direction of the first printed circuit board are formed at the step of preparing the first printed circuit board, and wherein the method further comprises a step of forming a protective film to cover the first conductive patterns such that the first insulating board is exposed between two of the first conductive patterns, which are adjacent to each other, in the area pressed by the heat-pressing tool.

7. The method in claim 6, wherein the projections heat press the overlapped portion between the two of the first conductive patterns at the step of heat pressing.

8. The method in claim 6, wherein a plurality of the second conductive patterns that are substantially parallel to each other in the longitudinal direction of the second printed circuit board are formed at the step of preparing the second printed circuit board such that each second land of the second conductive patterns has a predetermined distance from an end of the second printed circuit board, and wherein the second insulating board is bonded to the first insulating board between the two of the first conductive patterns in the predetermined distance.

9. A method for connecting a pair of printed circuit board comprising steps of:

preparing a first printed circuit board by forming a first conductive pattern, which includes a first land, on a first insulating board substantially made of thermoplastic resin;

preparing a second printed circuit board by forming a second conductive pattern, which includes a second land, on a second insulating board;

overlapping the first and second printed circuit boards such that the first and second lands confront each other;

heat pressing an overlapped portion of the first and second printed circuit boards with a heat-pressing tool at a temperature higher than the melting point of the thermoplastic resin while the first insulating board is cooled at an area adjacent to an area pressed by the heat-pressing tool during the step of heat pressing such that the temperature of the first insulating board is kept lower than the melting point at the area adjacent to the area pressed by the heat-pressing tool, wherein the first and second lands are electrically connected with the solder and the thermoplastic resin is softened and plastically deformed to bond the first insulating board to the second insulating board at the step of heat pressing.

10. The method in claim 9, wherein the area adjacent to the area pressed by the heat-pressing tool is a frame-like region that encloses the area pressed by the heat-pressing tool at the step of heat pressing.

11. The method in claim 9, wherein the area adjacent to the area pressed by the heat-pressing tool is two bar-like regions, between which the area pressed by the heat-pressing tool is located at the step of heat pressing.

12. The method in claim 11, wherein a plurality of the first conductive patterns that are substantially parallel to each other in the longitudinal direction of the first printed circuit board are formed at the step of preparing the first printed circuit board, and wherein the two regions are adjacent to the area pressed by the heat-pressing tool in the longitudinal direction.

13. The method in claim 9, wherein the area adjacent to the area pressed by the heat-pressing tool is a bar-like region.

14. The method in claim 13, wherein a plurality of the first conductive patterns that are substantially parallel to each other in the longitudinal direction of the first printed circuit board are formed at the step of preparing the first printed circuit board, and wherein the bar-like region is adjacent to the area pressed by the heat-pressing tool in the longitudinal direction.

15. The method in claim 14, wherein the area pressed by the heat-pressing tool is located at an end of the first printed circuit board in the longitudinal direction, and wherein the bar-like region is located at a side of the area pressed by the heat-pressing tool far from the end in the longitudinal direction.

16. The method in claim 9, wherein a cooling member is placed at a side of the area pressed by the heat-pressing tool far from an end of the first printed circuit board in the longitudinal direction of the first printed circuit board to cool the area adjacent to the area pressed by the heat-pressing tool at the step of heat pressing.

17. The method in claim 16, wherein the overlapped portion is heat pressed by the heat-pressing tool with a thin-palate-like intervening member in-between, wherein the cooling member is in contact with the intervening member.

18. The method in claim 17, wherein the intervening member has a thermal conductivity of 0.15 W/mm°

C. or lower.

19. The method in claim 9, wherein the thermoplastic resin includes one of polyethylenenaphthalate, polyethylenetelephthalate, polyetherimide, polyetheretherketone, and liquid crystal polymer.

20. The method in claim 9, wherein the overlapped portion is heated by the heat-pressing tool from the side where a surface of the first printed circuit board is exposed at the step of heat pressing, wherein a separator is placed on the surface, and wherein the surface is in contact with the separator during the step of heat pressing.

21. A pair of connected printed circuit boards comprising:

a first printed circuit board, which includes a first insulating board substantially made of thermoplastic resin and a first conductive pattern having a first land, wherein the first conductive pattern is located on the first insulating board; and

a second printed circuit board, which includes a second insulating board and a second conductive pattern having a second land, wherein the second conductive pattern is located on the second insulating board, wherein the first land is in electrical connect with the second land, wherein the thermoplastic resin of the first insulating board is in contact with the second insulating board in the proximity of the first and second lands, the thickness of the first insulating board on the first land is 20% or more of the thickness at the rest of the first insulating board.

22. The pair of connected printed circuit boards claim in 21, wherein the thermoplastic resin includes one of polyethylenenaphthalate, polyethylenetelephthalate, polyetherimide, polyetheretherketone, and liquid crystal polymer.