Formed PCB

• US 8,477,492 B2
• Filed: 08/19/2010
• Issued: 07/02/2013
• Est. Priority Date: 08/19/2010
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Rothkopf, Fletcher R., Hobson, Phillip M., Mittleman, Adam, Shedletsky, Anna-Katrina
• Primary Examiner(s): Estrada, Angel R
• Assistant Examiner(s): LOPEZ CRUZ, DIMARY S
• Application Number:
  US12/859,712
• Publication Number:
  US 20120044637A1
• Time in Patent Office: 1,048 Days
• Field of Search: 361/749, 361/752, 361/760, 361/761, 361/784, 361/796, 361/679.01, 361/679.02, 361/679.55, 361/679.56, 361/748, 174/250, 174/254
• US Class Current: 361/679.55
• CPC Class Codes: G06F 1/1626 with a single-body enclosure integrating a flat display, e.g. Personal Digital Assistants [PDAs]
• CPC Class Codes: G06F 1/1658 related to the mounting of internal components, e.g. disc drive or any other functional module
• CPC Class Codes: G06F 1/181 Enclosures for portable computers G06F1/1613
• CPC Class Codes: H05K 1/0281 Reinforcement details thereof
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/056 Folded around rigid support or component
• CPC Class Codes: H05K 7/1427 Housings
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base

Abstract

Methods for forming PCBs that can be used in a portable computing device are described. The PCBs can be installed in the portable computing device in a bent configuration. In a particular embodiment, a contiguously formed PCB can be shaped with two large regions connected a thin connector portion. The thin connector portion can connect components one each of the two large regions and can be used in lieu of a flex connector. In one embodiment, the PCB can be formed from multiple layers including trace and substrate layers. The trace and substrate layer can be adjusted to affect the stiffness of the PCB in various regions, such as to allow the PCB to hold a bent configuration after a bending moment is applied.

Claims

1. A portable electronic device comprising:

an enclosure;

a battery installed within the enclosure;

a number of device components installed within the enclosure; and

a main logic board, including a processor and a memory, formed on a contiguous multi-layered printed circuit board, configured to receive power from the battery and control the portable electronic device, the printed circuit board comprising;

a first custom shaped portion configured to fit in a first space between the battery and the number of device components including the processor;

a second custom shaped portion configured to fit in a second space between the battery and the number of device components including circuitry for operating the portable electronic device; and

a thin and narrow third portion installed in a pathway between the number of device components and the battery that connects the first space and the second space wherein the thin and narrow shaped portion only includes traces for providing data or power connections between the first custom shaped portion and the second custom shaped portion.

2. The portable electronic device of claim 1, wherein the first custom shaped portion or the second custom shaped portion are rectangular shaped.

3. The portable electronic device of claim 1, wherein the first custom shaped portion or the second custom shaped portion includes one or more curved portions.

4. The portable electronic device of claim 1, wherein the first custom shaped portion and the second custom shaped portion are installed at an angle relative to one another.

5. The portable electronic device of claim 1, wherein the first custom shaped portion and the second custom shaped portion are installed at different heights relative to one another.

6. The portable electronic device of claim 1, wherein the pathway between the first space and the second space includes one or more steps or curves and the third portion is bent to follow the one or more steps or the curves.

7. A portable electronic device comprising:

a housing;

a battery installed within the housing;

first and second device components installed within the housing; and

a printed circuit board configured to receive power from the battery, comprising;

a processor and a memory attached to the printed circuit board,

a first region configured for alignment with a top end of the battery,

a second region configured for alignment with a bottom end of the battery, and

a third region that extends between the first region and the second region, configured to conform proximately to one side of the battery such that the first region, the second region, and the third region partially surround the battery.

8. The portable electronic device of claim 7, wherein the printed circuit board is installed in the housing such that the first region is secured at a height within the housing that is different from a height at which the second region is installed.

9. The portable electronic device of claim 7, wherein the first device component is attached to the first region.

10. The portable electronic device of claim 9, wherein the second device component is attached to the second region.

11. The portable electronic device of claim 10, wherein the third region includes a number of traces coupled between the first component and the second component.

12. The portable electronic device of claim 7, wherein the printed circuit board includes a trace layer having at least one conductive trace and stiffening material.

13. The portable electronic device of claim 7, wherein the printed circuit board includes a metal layer formed from a material selected to increase the stiffness of the printed circuit board, wherein said metal layer is free of traces.

14. A portable electronic device comprising:

an enclosure;

a battery installed within the enclosure;

an electronic component installed within the enclosure; and

a contiguous printed circuit board having a first portion and a second portion, wherein the printed circuit board is bent so that the electronic component is interposed between the first portion and the second portion; and

a plurality of additional electronic components attached to the printed circuit board.

15. The portable electronic device defined in claim 14 wherein the printed circuit board further comprises:

a substrate layer;

a trace layer; and

a metal layer.

16. The portable electronic device defined in claim 15 wherein the metal layer is configured to stiffen the printed circuit board such that the printed circuit board remains in a bent configuration.

17. The portable electronic device defined in claim 14, wherein the plurality of additional electronic components are attached to a common surface of the printed circuit board.

18. The portable electronic device of claim 14, wherein at least one of the plurality of additional electronic components is attached to a first surface of the printed circuit board and at least one of the plurality of additional electronic components is attached to an opposing second surface of the printed circuit board.

19. The portable electronic device of claim 14, wherein the electronic component has a curved portion and wherein a portion of the printed circuit board is bent to follow a curvature of the curved portion.

20. The portable electronic device of claim 14, wherein the printed circuit board is bent in multiple locations.

21. The portable electronic device of claim 14, wherein the printed circuit board comprises a metal layer that is formed from a shape memory alloy, wherein the shape memory alloy is formed in a shape that corresponds to the bent shape of the printed circuit board.