Fabric signal path structures for flexible devices

• US 9,883,583 B2
• Filed: 09/02/2015
• Issued: 01/30/2018
• Est. Priority Date: 09/02/2015
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Cousins, Benjamin A., Stiehl, Kurt R., Smith, Samuel G., Mayer, Kirk M., Hegde, Siddhartha, Kuna, Melody
• Primary Examiner(s): Norris, Jeremy C
• Application Number:
  US14/843,617
• Publication Number:
  US 20170060192A1
• Time in Patent Office: 881 Days
• CPC Class Codes: A45C 13/005 Hinges
• CPC Class Codes: A45C 2011/003 for portable computing devices, e.g. laptop, tablet, netbook, game boy, navigation system, calculator
• 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 1/1656 Details related to functional adaptations of the enclosure, e.g. to provide protection against EMI, shock, water, or to host detachable peripherals like a mouse or removable expansions units like PCMCIA cards, or to provide access to internal components for maintenance or to removable storage supports like CDs or DVDs, or to mechanically mount accessories mounting of accessories to a computer display G06F1/1607; display hoods G06F1/1603; cooling arrangements for portable computers G06F1/203
• CPC Class Codes: G06F 1/1662 Details related to the integrated keyboard
• CPC Class Codes: G06F 1/1683 for the transmission of signal or power between the different housings, e.g. details of wired or wireless communication, passage of cabling
• CPC Class Codes: H04M 1/185 Improving the rigidity of the casing or resistance to shocks
• CPC Class Codes: H04M 1/23 Construction or mounting of dials or of equivalent devices; Means for facilitating the use thereof by improving visibility H04M1/22
• CPC Class Codes: H05K 1/028 Bending or folding regions of flexible printed circuits H05K1/0283 takes precedence
• CPC Class Codes: H05K 1/0296 Conductive pattern lay-out details not covered by sub groups H05K1/02 - H05K1/0295 H05K1/11 takes precedence; lay-out adapted to mounted component configuration H05K1/18
• CPC Class Codes: H05K 1/038 Textiles used as reinforcing materials for organic insulating substrates H05K1/0366
• 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 1/09 Use of materials for the conductive, e.g. metallic pattern
• 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 2201/05 Flexible printed circuits [FPCs]
• CPC Class Codes: H05K 3/06 the conductive material being removed chemically or electrolytically, e.g. by photo-etch process semi-additive methods H05K3/108
• CPC Class Codes: H05K 3/10 in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
• CPC Class Codes: H05K 3/108 by semi-additive methods; masks therefor characterised by metallic etch mask H05K3/062; electroplating methods or apparatus H05K3/241

Abstract

An electronic device such as a cover for a portable device may be provided with a body having hinge portions. The hinge portions may allow the body to bend about one or more bend axes. The cover may have electrical components such as a keyboard. A keyboard may be mounted at one end of the cover and a connector may be mounted at an opposing end of the cover. A flexible fabric signal path structure may be formed from metal traces on a flexible fabric substrate. At one end of the cover, the flexible fabric signal path structure may be coupled to a printed circuit in the keyboard using conductive adhesive. At the opposing end of the cover, the metal traces on the flexible fabric substrate may be coupled to the connector.

Claims

1. A flexible fabric signal path structure for conveying signals in an electronic device, comprising:

a fabric substrate; and

a layer of metal on the fabric substrate that is patterned to form a plurality of parallel metal traces, wherein the layer of metal penetrates through openings in the fabric substrate.

2. The flexible fabric signal path structure defined in claim 1 wherein the fabric substrate comprises a woven fabric layer.

3. The flexible fabric signal path structure defined in claim 2 wherein the woven fabric layer comprises polymer strands of material.

4. The flexible fabric signal path structure defined in claim 3 wherein the polymer strands of material comprise nylon.

5. The flexible fabric signal path structure defined in claim 3 wherein the layer of metal includes multiple metal layers of different metals.

6. The flexible fabric signal path structure defined in claim 3 wherein the layer of metal includes at a first metal layer and a second metal layer on the first metal layer.

7. The flexible fabric signal path structure defined in claim 6 wherein the first metal layer comprises a metal selected from the group consisting of:

copper and nickel.

8. The flexible fabric signal path structure defined in claim 7 wherein the second layer comprises a material selected from the group consisting of silver, copper, and tin.

9. The flexible fabric signal path structure defined in claim 3 wherein the layer of metal comprises multiple layers of metal selected from the group consisting of:

electroless metal and electrolytic plated metal.

10. The flexible fabric signal path structure defined in claim 1 wherein the metal traces have widths of greater than 0.5 cm.

11. A cover for an electronic device, comprising:

a body having hinge portions that allow the body to bend about at least one bend axis;

electrical contacts formed on an outer surface of the body; and

a flexible fabric signal path structure within the body that overlaps the bend axis and that has signal paths that carry signals across the bend axis, wherein the signal paths are electrically coupled to the electrical contacts.

12. The cover defined in claim 11 further comprising:

a printed circuit having metal pads; and

conductive adhesive interposed between the signal paths on the flexible fabric signal path structure and the printed circuit to electrically couple the signal paths to the metal pads on the printed circuit.

13. The cover defined in claim 12 further comprising insulating adhesive that surrounds the conductive adhesive.

14. The cover defined in claim 13 further comprising key switches mounted on the printed circuit that form part of a keyboard.

15. The cover defined in claim 14 wherein the flexible fabric signal path structure has first and second opposing ends, wherein the conductive adhesive is formed at the first end, wherein the cover further comprises a connector that is coupled to the flexible fabric signal path structure at the second end, and wherein the electrical contacts form part of the connector.

16. The cover defined in claim 15 wherein the signal paths comprise conductive strands of material and wherein the flexible fabric signal path structure comprises a layer of fabric that includes the strands material.

17. The cover defined in claim 15 wherein the flexible fabric signal path structure has a fabric substrate and wherein the signal paths comprise metal traces on the fabric substrate.

18. The cover defined in claim 17 wherein the metal traces comprise electroplated metal.

19. The cover defined in claim 18 wherein the metal traces run perpendicular to the bend axis and wherein the fabric substrate comprises strands of material that are oriented at a non-zero angle of 1-10°

from the bend axis.

20. A cover for a tablet computer, comprising:

a body having opposing first and second ends and having a hinge portion that allows the body to bend about a bend axis at a location between the first and second ends;

a keyboard having a printed circuit;

a connector; and

a flexible fabric signal path structure in the body that has metal traces that are coupled to the keyboard at the first and that are coupled to the connector at the second end.

21. The cover defined in claim 20 wherein the flexible fabric signal path structure comprises a woven fabric coated with electroplated metal traces that carry signals between the keyboard and the connector.

22. The cover defined in claim 21 wherein the metal traces have widths that are greater than 0.5 cm.