Reflow solderable flexible circuit board — to — flexible circuit board connector reinforcement

• US 9,474,154 B2
• Filed: 07/18/2014
• Issued: 10/18/2016
• Est. Priority Date: 07/18/2014
• Status: Active Grant

• Current Assignee: Starkey Laboratories Incorporated
• Original Assignee: Starkey Laboratories Incorporated
• Inventors: Johansson, Susie, Lambert, Andy
• Primary Examiner(s): Chen, Xiaoliang
• Application Number:
  US14/335,513
• Publication Number:
  US 20160021742A1
• Time in Patent Office: 823 Days
• Field of Search: 174/251, 174/254, 174/268, 174/535, 174/541, 174/557, 439/62, 439 65- 67, 439/69, 439/108, 439/260, 439/607.05, 439/620.21, 439/660, 396/176, 396/542, 345/173, 361/679.02, 361/749, 361/752, 361/760
• US Class Current: 1/1
• CPC Class Codes: H04R 25/603 of mechanical or electronic switches or control elements
• CPC Class Codes: H04R 25/609 of circuitry of electronic switches or control elements H04R25/603
• CPC Class Codes: H05K 1/0281 Reinforcement details thereof
• CPC Class Codes: H05K 1/0393 Flexible materials H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups
• CPC Class Codes: H05K 1/111 Pads for surface mounting, e.g. lay-out
• 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 2201/10189 Non-printed connector
• CPC Class Codes: H05K 3/303 Surface mounted components, e.g. affixing before soldering, aligning means, spacing means H05K3/32 takes precedence
• CPC Class Codes: H05K 3/34 by soldering
• CPC Class Codes: H05K 3/363 by soldering

Abstract

A system embodiment may include a first flexible substrate with a first number of conductors, the first flexible substrate configured to be mechanically flexed. The system may further include a surface mounted device (SMD) mounted on the first flexible substrate and connected to at least some of the first number of conductors, and a first board-to-board connector element connected to at least some of the first number of conductors on a first side of the substrate. The first board-to-board connector element is configured to mechanically connect to a second board-to-board connector element on a second flexible substrate and to electrically connect at least some of the first number of conductors in the first flexible substrate to at least some conductors in the second flexible substrate. The system may further include a stiffener board connected by solder to a second side of the first flexible substrate opposite the board-to-board connector element.

Claims

1. A system, comprising:

a first flexible substrate with a first number of conductors, the first flexible substrate configured to be mechanically flexed, and the first flexible substrate having at least a first solder pad, a second solder pad and third solder pad;

a surface mounted device (SMD) soldered to the first solder pad of the first flexible substrate and connected to at least some of the first number of conductors;

a first board-to-board connector element soldered to the second solder pad that is on a first side of the first flexible substrate, the first board-to-board connector element connected to at least some of the first number of conductors, the first board-to-board connector element being configured to mechanically connect to a second board-to-board connector element on a second flexible substrate and to electrically connect at least some of the first number of conductors in the first flexible substrate to at least some conductors in the second flexible substrate; and

a stiffener board soldered to a third solder pad that is on a second side of the first flexible substrate opposite the second solder pad and the first board- to-board connector element.

2. The system of claim 1, wherein the stiffener board includes a rigid material that is not solid metal.

3. The system of claim 1, wherein the stiffener board includes FR4 board, acrylic, epoxy, polyimide, kapton, ceramic, or silicon.

4. The system of claim 1, wherein the first board-to-board connector element includes one of a board-to-board connector plug or a board-to-board connector receptacle, and the second board-to-board connector element includes the other of the board-to-board connector plug or the board-to-board connector receptacle.

5. The system of claim 1, wherein the SMD is mounted on the first side of the first flexible substrate.

6. The system of claim 1, wherein the SMD is mounted on the second side of the first flexible substrate.

7. The system of claim 1, wherein the SMD is a first SMD mounted on the first side of the first flexible substrate, the system further including a second SMD mounted on the second side of the first flexible substrate.

8. The system of claim 1, wherein the stiffener board is configured to provide mechanical support without providing an electrical function for the system.

9. A system, comprising:

a first flex circuit segment, including;

a first flexible substrate with a first number of conductors, the first flexible substrate configured to be mechanically flexed, and the first flexible substrate having at least a first solder pad, a second solder pad and third solder pad;

a first surface mounted device (SMD soldered to the first solder pad of the first flexible substrate and connected to at least some of the first number of conductors;

a first board-to-board connector element soldered to the second solder pad of the first flexible substrate that is on a first side of the first flexible substrate, the first board-to-board connector element connected to at least some of the first number of conductors; and

a first stiffener board soldered to a third solder pad of the first flexible substrate that is on a second side of the first flexible substrate opposite the second solder pad and the first board-to-board connector element; and

a second flex circuit segment, including;

a second flexible substrate with a second number of conductors, the second flexible substrate configured to be mechanically flexed and the second flexible substrate having at least a first solder pad, a second solder pad and third solder pad;

a second SMD soldered to the first solder pad of the second flexible substrate and connected to at least some of the second number of conductors;

a second board-to-board connector element soldered to the second solder pad that is on a first side of the second flexible substrate, the second board-to-board connector element connected to at least some of the second number of conductors, wherein the first and second board-to-board connector elements are configured to mechanically connect to each and to electrically connect at least some of the first number of conductors to at least some of the second number of conductors; and

a second stiffener board soldered to a third solder pad that is on a second side of the second flexible substrate opposite the second solder pad and the second board-to-board connector element.

10. The system of claim 9, wherein a first mounting pad is used to mount the first board-to-board connector element to the first side of the first flexible substrate, and a second mounting pad is used to mount the second board-to-board connector element to the second side of the first flexible substrate, and wherein the first mounting pad and the second mounting pad have compatible designs with identical footprints, and wherein outer solder balls are used to mechanically connect the first board-to-board connector element to the first mounting pad.

11. The system of claim 9, wherein each of the first and second flexible substrates have a rectangular footprint.

12. The system of claim 9, wherein the system is a hearing assistance system, the first flex circuit segment includes a main board, and the second flex circuit segment includes at least one microphone.

13. The system of claim 12, wherein the first connector element mounted to the main board is a board-to-board connector receptacle, and wherein the main board includes another board-to-board connector receptacle mounted to one of the first or second sides, and another stiffener board mounted to the other of the first or second sides.

14. The system of claim 9, wherein each of the first and second stiffener boards includes a rigid material that is not solid metal.