MOUNTING AND CONFORMAL COATING SUPPORT STRUCTURE TO FLEX ASSEMBLY TO PREVENT TRACE AND COMPONENT CRACKING

• US 20130053098A1
• Filed: 09/22/2011
• Published: 02/28/2013
• Est. Priority Date: 08/31/2011
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: KWONG, Kelvin, DINH, Richard Hung Minh, KOLE, Jared Mitchell
• Granted Patent: US 9,030,832 B2
• Time in Patent Office: Days
• US Class Current: 455/556.1
• CPC Class Codes: G01J 1/0214 Constructional arrangements for removing stray light
• CPC Class Codes: G01J 1/0233 Handheld
• CPC Class Codes: G01J 1/0271 Housings; Attachments or accessories for photometers
• CPC Class Codes: G01J 1/0488 with spectral filtering
• CPC Class Codes: G01J 1/06 Restricting the angle of incident light
• CPC Class Codes: G01S 17/04 Systems determining the presence of a target
• CPC Class Codes: G01S 7/4811 common to transmitter and receiver
• CPC Class Codes: H01L 31/02162 for filtering or shielding light, e.g. multicolour filters for photodetectors
• CPC Class Codes: H01L 31/02325 the optical elements not being integrated nor being directly associated with the device
• CPC Class Codes: H01L 31/167 the light sources and the devices sensitive to radiation all being semiconductor devices characterised by potential barriers
• CPC Class Codes: H01L 31/173 formed in, or on, a common substrate
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing

Abstract

A compact proximity sensor for use in a portable computing device is described. In particular various embodiments of a proximity sensor which fits in an extremely small portion of a cellular phone, and accurately determine the presence of a user'"'"'s head in close proximity to a surface of the cellular phone. In particular, a high yield assembly process for installing the compact proximity sensor is described.

Claims

1. A flex connector assembly for connecting electrical components in a small form factor communication device, comprising:

a main body portion, comprising;

a first body portion having a first connection area arranged to receive and electrically connect to a first component,

a second body portion having a second connection area arranged to receive and electrically connect to a second component,

a support structure mechanically attached to a back side of the second body portion, comprising a back support plate formed of rigid material, and a conformal coating of resilient material; and

a folding flexible portion connecting the first body portion and the second body portion, wherein during an assembly operation and subsequent to the securing of the first component to the first body portion and the second component to the second body portion, the secured first component and the secured second component are brought in close proximity to each other by folding the folding flexible portion into a compact folded arrangement wherein the back support plate and the conformal coating of resilient material substantially reduce a likelihood of damaging traces within the second body portion during the folding by eliminating a bending force on the second body portion.

2. The flex connector assembly as recited in claim 1, further comprising:

a third body portion having a third connection area; and

a third flexible substrate connecting the third body portion to the main body portion.

3. The flex connector assembly as recited in claim 2, further comprising:

a fourth body portion having a fourth connection area; and

a fourth flexible substrate connecting the fourth body portion to the main body portion independent of the third body portion.

4. The flex connector assembly as recited in claim 3, where first component is an audio circuit arranged to provide audible sounds to an end user.

5. The flex connector assembly as recited in claim 4, wherein the second component is a proximity sensor arranged to detect the presence of an object within a pre-determined distance of the proximity sensor and provide a signal that indicates that the object is within the pre-determined distance.

6. The flex connector assembly as recited in claim 5, wherein the compact folded arrangement of the flex connector assembly provides that the audio circuit and the proximity sensor are placed in close proximity to each other and that the proximity sensor is recessed with respect to the audio circuit.

7. A portable computing device, comprising

a housing having an opening;

a display assembly having a size and shape in accordance with the display assembly;

a protective layer disposing within the opening, the protective layer having an exterior surface and an interior surface;

a proximity sensor for detecting a presence of an object within a first distance of the exterior surface of the protective layer;

an audio circuit for providing audible sound; and

flex connector assembly, comprising;

a main body portion, comprising;

a first body portion having a first connection area arranged to receive and electrically connect to a first component,

a second body portion having a second connection area arranged to receive and electrically connect to a second component,

a support structure mechanically attached to a back side of the second body portion, comprising a back support plate formed of rigid material, and a conformal coating of resilient material, and

a folding flexible portion connecting the first body portion and the second body portion, wherein during an assembly operation and subsequent to the securing of the first component to the first body portion and the second component to the second body portion, the secured first component and the secured second component are brought in close proximity to each other by folding the folding flexible portion into a compact folded arrangement wherein the back support plate and the conformal coating of resilient material substantially reduce a likelihood of damaging traces within the second body portion during the folding by eliminating a bending force on the second body portion.

8. The portable computing device as recited in claim 7, further comprising:

a third body portion having a third connection area; and

a third flexible substrate connecting the third body portion to the main body portion.

9. The portable computing device as recited in claim 8, the flex connector assembly further comprising:

a fourth body portion having a fourth connection area; and

a fourth flexible substrate connecting the fourth body portion to the main body portion independent of the third body portion.

10. The portable computing device as recited in claim 9, wherein the third connection area is electrically connected to main logic board (MLB).

11. The portable computing device as recited in claim 10, wherein the fourth connection area is electrically connected to a hold button.

12. The portable computing device as recited in claim 7, comprising:

a light emitting portion,

a light detecting portion in proximity to the light emitting portion,

a uniform transparent structure disposed at the lower surface of the protective layer,

a collimating portion disposed between the light emitting portion and the light detecting portion, wherein the proximity sensor detects a presence of an object at or within an activation distance of the exterior surface of the protective layer by establishing an optical path between the light emitting portion and the light detecting portion, wherein light passing from the light emitting portion to the light detecting portion along the optical path is directed by the collimating portion and modified by the optically opaque layer.

13. The portable computing device as recited in claim 12, wherein the portable computing device is a small form factor smart phone.

14. A method of assembly of a small form factor communication device, comprising:

providing a flex connector assembly for connecting electrical components in the small form factor communication device having housing, comprising;

a main body portion, comprising;

a first body portion having a first connection area electrically connected to a first component,

a second body portion having a second connection area electrically connected to a second component, and

a folding flexible portion connecting the first body portion and the second body portion;

placing the flex connector assembly in the housing;

bringing the first and second components in close proximity to each other in the housing by folding the folding flexible portion into a compact folded arrangement, wherein the compact folded arrangement of the flex connector assembly provides that the first component and the second component are placed in close proximity to each other and that the proximity sensor is recessed with respect to the audio circuit, wherein a support structure mechanically attached to a back side of the second body portion, comprising a back support plate formed of rigid material, and a conformal coating of resilient material substantially reduces a likelihood of damaging traces within the second body portion during the folding by eliminating a bending force on the second body portion.

15. The method as recited in claim 14, further comprising:

connecting a main logic board (MLB) to a third connection area of the flex connector assembly, the third connection area associated with a third body portion connected to the main body portion by a third flexible substrate.

16. The method as recited in claim 15, further comprising:

connecting a hold button to a fourth connection area of the flex connector assembly, the fourth connection area associated with a fourth body portion connected to the main body portion by a fourth flexible substrate.

17. The method as recited in claim 16, further comprising:

placing a display assembly into the housing, the display assembly having a display unit and a protective layer such that the proximity sensor detects the presence of an end user within a pre-determined distance of an exterior surface of the protective layer.