GB2616416A - Electrical interconnect and method of manufacture - Google Patents

Electrical interconnect and method of manufacture Download PDF

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Publication number
GB2616416A
GB2616416A GB2202988.8A GB202202988A GB2616416A GB 2616416 A GB2616416 A GB 2616416A GB 202202988 A GB202202988 A GB 202202988A GB 2616416 A GB2616416 A GB 2616416A
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GB
United Kingdom
Prior art keywords
fpc
support structure
moveable component
folded
plane
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
GB2202988.8A
Other versions
GB202202988D0 (en
Inventor
Eddington Robin
Pantelidis Konstantinos
Hart Oliver
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Cambridge Mechatronics Ltd
Original Assignee
Cambridge Mechatronics Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cambridge Mechatronics Ltd filed Critical Cambridge Mechatronics Ltd
Priority to GB2202988.8A priority Critical patent/GB2616416A/en
Publication of GB202202988D0 publication Critical patent/GB202202988D0/en
Publication of GB2616416A publication Critical patent/GB2616416A/en
Pending legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00Printed circuits
    • H05K1/18Printed circuits structurally associated with non-printed electric components
    • H05K1/189Printed circuits structurally associated with non-printed electric components characterised by the use of a flexible or folded printed circuit
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00Printed circuits
    • H05K1/02Details
    • H05K1/0277Bendability or stretchability details
    • H05K1/028Bending or folding regions of flexible printed circuits
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/64Imaging systems using optical elements for stabilisation of the lateral and angular position of the image
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/64Imaging systems using optical elements for stabilisation of the lateral and angular position of the image
    • G02B27/646Imaging systems using optical elements for stabilisation of the lateral and angular position of the image compensating for small deviations, e.g. due to vibration or shake
    • GPHYSICS
    • G03PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03BAPPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
    • G03B2205/00Adjustment of optical system relative to image or object surface other than for focusing
    • G03B2205/0007Movement of one or more optical elements for control of motion blur
    • G03B2205/0015Movement of one or more optical elements for control of motion blur by displacing one or more optical elements normal to the optical axis
    • GPHYSICS
    • G03PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03BAPPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
    • G03B2205/00Adjustment of optical system relative to image or object surface other than for focusing
    • G03B2205/0007Movement of one or more optical elements for control of motion blur
    • G03B2205/0023Movement of one or more optical elements for control of motion blur by tilting or inclining one or more optical elements with respect to the optical axis
    • HELECTRICITY
    • H04ELECTRIC COMMUNICATION TECHNIQUE
    • H04NPICTORIAL COMMUNICATION, e.g. TELEVISION
    • H04N23/00Cameras or camera modules comprising electronic image sensors; Control thereof
    • H04N23/60Control of cameras or camera modules
    • H04N23/68Control of cameras or camera modules for stable pick-up of the scene, e.g. compensating for camera body vibrations
    • H04N23/682Vibration or motion blur correction
    • H04N23/685Vibration or motion blur correction performed by mechanical compensation
    • H04N23/687Vibration or motion blur correction performed by mechanical compensation by shifting the lens or sensor position
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00Printed circuits
    • H05K1/02Details
    • H05K1/03Use of materials for the substrate
    • H05K1/0393Flexible materials
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/05Flexible printed circuits [FPCs]
    • H05K2201/056Folded around rigid support or component
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10007Types of components
    • H05K2201/10083Electromechanical or electro-acoustic component, e.g. microphone

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Multimedia (AREA)
  • Signal Processing (AREA)
  • Structures For Mounting Electric Components On Printed Circuit Boards (AREA)
  • Structure Of Printed Boards (AREA)

Abstract

An electrical interconnect for connecting a first device part to a second relatively movable device part using a folded flexible printed circuit board PCB eg a FPC. The method of making the FPC comprises folding an initially flat flexible printed circuit (fig 4a), which defines a first plane, along two or more fold lines 4, 6, 8, 8a, 10 which are all preferably in that plane, and then electrically connecting between a support structure and relatively movable component. The folded FPC (fig 4b) may have two portions perpendicular to each other and to the original flat plane. The folded FPC may have fold lines in the same plane or in a set of parallel planes. Bracket 38 may fix to a movable image sensor of a camera and portion 18 attaches to the non-moving support structure, such as a smartphone. Portion 18 may be in a plane parallel to the original plane via two parallel fold lines. Other possible movable components are a display panel or an illumination source, such a led, laser or projector. Preferably the FPC is folded to allow multiple degrees of freedom such as tilting about two axis, rotation about an axis, translation in three perpendicular directions. While figures 4a,b show a ring connecting to the component, alternative embodiment may comprise a pair of arms (figs 1a , 1b). Different portions of the FPC may have differing number of layers of conductive tracks. The construction may comprise an actuator assembly.

Description

Electrical interconnect and method of manufacture
Field
The present application relates to a method of manufacturing a device and an actuator assembly.
Background
Many electronic devices comprise a movable component which must be electrically connected to one or more other components in the device which do not move with the movable component. Such an electrical connection may be for the purposes of data and/or power transfer. Therefore, an electrical interconnect between the movable component and the non-moving component is required which does not hinder movement of the movable component.
An example of a device in which such an interconnect may be required is a camera. In a camera, various degrees of movement of a movable component may be required for example for the purposes of optical image stabilisation (01S) and/or autofocus. The movable component in a camera may be, for example, a lens assembly, an image sensor, or a module comprising the image sensor and the lens assembly.
An example of an electrical interconnect is a flexible printed circuit, referred to hereinafter as an FPC. A conventionally-constructed FPC may comprise a flexible substrate made of a suitable material, for example a plastic such as polyimide, PEEK or polyester and conductive (e.g. copper) tracks.
Some FPCs require permanent folds to be set into them during assembly, for example to facilitate compliance in two perpendicular directions (e.g. for the purpose of OIS in a camera). If such fold lines are in various orientations, each time a fold line is required along an axis different to the previous fold lines, the FPC must be reorientated on the tool used for the folding. This increases the manufacture time and also cost.
The present disclosure is concerned with methods of manufacture and associated actuator assemblies which involve reduced time and cost of manufacture whilst maintaining compliance of the FPC so as not to hinder (or hinder as little as possible) the motion of the movable component relative to the non-moving component(s) of the device.
Summary
According to an aspect of the present invention, there is provided a method of manufacturing a device.
The method comprises: - folding a flat flexible printed circuit, FPC, which defines a first plane, along two or more fold lines, wherein all of the lines along which the FPC is folded lie in the first plane; and - electrically connecting the folded FPC between a moveable component of the device and a support structure of the device.
The moveable component is moveable relative to the support structure.
In some embodiments, electrically connecting the folded FPC between a moveable component of the device and a support structure of the device may comprise connecting the FPC to the support structure of the device and optionally to the moveable component of the device. In some embodiments, the moveable component may be already attached to the FPC (for example to a printed circuit board, PCB, which is connected to or integral with the FPC) when the FPC is folded.
An advantage of all of the lines along which the FPC is folded lying in the same plane is that the manufacture of the FPC is simplified. In particular, only a single tool is needed and all of the folds can be carried out in a single step. A further advantage is that the footprint of the FPC may be reduced, as compared to designs with more complicated fold configurations. This may lead to an increase in efficiency of the material used to produce the FPC, as a smaller area of material is required.
Additionally, such a design may be advantageous as compared to a design in which relatively long lengths of FPC are folded. If the length of FPC material that is being folded is shorter, for any given angular folding tolerance the actual positional error of the final geometry will be less. The benefit of this is that clearances around the FPC and/or moving components can be reduced which results in a smaller actuator design.
In some embodiments, the folded FPC may be configured to allow movement of the moveable component relative to the support structure along two perpendicular axes. The two perpendicular axes may be parallel to (or coplanar with) the first plane. i.e. the folded FPC may be configured to allow movement of the moveable component in the first plane or in a plane parallel to the first plane.
In some embodiments, the folded FPC may comprise a first planar portion and a second planar portion, wherein the first planar portion is substantially perpendicular to the second planar portion and the first and second portions are both substantially perpendicular to the plane defined by the flat FPC. In other words, two of the portions of the FPC which are perpendicular to the first plane are perpendicular to eachother. This may facilitate compliance of the FPC along two perpendicular axes.
In some embodiments, the moveable component may be an optical component such as a lens assembly (comprising one or more lenses), an image sensor assembly comprising an image sensor having a light-sensitive region, or a module comprising both a lens assembly and an image sensor assembly. As an example, the FPC may be compliant in two perpendicular axes to allow for movement of the optical component for the purposes of optical image stabilization (01S) or super-resolution.
In some embodiments, the moveable component may comprise a display panel (e.g. LCD, LCOS or MicroLED) or an illumination source (e.g. an image projector, LASER, VCSEL or an LED). As an example, such a moveable component may be moved for the purpose of wobulation or 3D sensing.
In some embodiments, the folded FPC may be configured to allow movement of the moveable component relative to the support structure along three perpendicular axes. In the case of an optical component (e.g. those listed above), such motion along a third axis may be for the purpose of autofocus. Accordingly, the FPC may be configured to allow movement of the moveable component to facilitate both autofocus and 015.
In some embodiments the folded FPC may be configured to allow rotation of the moveable component about an axis. The axis may be perpendicular to the first plane.
In some embodiments, the folded FPC is configured to allow tilting of the moveable component relative to the support structure about two perpendicular axes. The two perpendicular axes may be coplanar with or parallel to the first plane. In such embodiments, the moveable component may comprise a module comprising an image sensor assembly and a lens assembly. Such a module may be tilted for the purposes of 015, for example.
In some embodiments, the folded FPC comprises: (a) a portion which is perpendicular to the first plane and (b) a portion which lies in the first plane.
The FPC may comprise a greater number of layers of conductive tracks over at least some of the portion which lies in the first plane than over at least some of the portion which is perpendicular to the first plane. In other words, some (or, in some embodiments, all) of the FPC which remains in the plane of the flat FPC may have a higher number of layers than some (or all) portions which are, when the FPC is in the folded state, perpendicular to the first plane. For example, some or all portions of the FPC which remain in the plane of the flat FPC may comprise 4 layers of conductive tracks (separated by insulating layers), whereas some or all portions of the FPC which are perpendicular to those 4-layer portions may comprise 2 layers of conductive tracks. The use of a greater number of layers in the portions which remain in the plane of the flat FPC may reduce the footprint of the FPC in that plane. The use of a relatively-lower number of layers in the perpendicular sections increases compliance of the FPC along those sections which allows for freer movement of the moveable component relative to the support structure.
In some embodiments, the FPC may extend in a loop around the movable component. In some embodiments, the FPC comprises first, second, third and fourth sides, wherein the first side is opposite the third side and the second side is opposite the fourth side. In some embodiments the method comprises connecting the moveable component to the FPC on its first side and the support structure to the FPC on its third side. In other words, the connection to the moveable component is on a side of the FPC which is opposite to the side on which the FPC is connected to the support structure. Therefore, the moving and static ends of the FPC are on opposing sides. This allows the flexible length of the FPC arms to be increased therefore allowing a reduction in stiffness of the structure.
In some embodiments, the FPC may comprise at least one fold line on each of its four sides. In some embodiments, the FPC may comprise a portion which is perpendicular or substantially perpendicular to the first plane on each of its first sides.
In some embodiments, the method comprises connecting the moveable component to the FPC on its first side and the support structure to the FPC on its second side. In other words, the moveable component and the support structure are connected to the FPC on adjacent sides of the FPC.
In some embodiments, the method may comprise folding the flat FPC along all of its fold lines in one operation and optionally using a single tool.
In some embodiments the method may include attaching an additional layer to the FPC at one or more of the fold lines. For example, the additional layer may comprise steel, for example a steel strip. Such an additional layer may help hold the fold accurately without the need of any heat curing steps.
According to another aspect of the present disclosure, there is provided an actuator assembly comprising: - a support structure; a moveable component which is moveable relative to the support structure along three perpendicular axes; and a flexible printed circuit, FPC, which provides an electrical connection between the moveable component and the support structure.
The FPC is folded along two or more fold lines and the FPC is configured to allow movement of the moveable component relative to the support structure along the three perpendicular axes. Additionally, either all of the lines along which the FPC is folded lie in a plane; or each of the lines along which the FPC is folded lie in one of a plurality of planes, wherein the plurality of planes are parallel to eachother.
According to another aspect of the present disclosure, there is provided an actuator assembly comprising: - a support structure; a moveable component which is moveable relative to the support structure; and - a flexible printed circuit, FPC, which provides an electrical connection between the moveable component and the support structure. The FPC is folded along two or more fold lines and the FPC is configured to allow tilting of the moveable component relative to the support structure about two perpendicular axes. Additionally, either: all of the lines along which the FPC is folded lie in a plane; or each of the lines along which the FPC is folded lie in one of a plurality of planes, wherein the plurality of planes are parallel to eachother.
In some embodiments the FPC may comprise a connecting portion connected to one of the support structure and moveable component. At least part of the connecting portion may lie in the same plane at least one of the fold lines of the FPC. In some embodiments the connecting portion is connected to the support structure and provides the only connection between the FPC and the support structure. In some embodiments the FPC may further comprise a further connecting portion which is connected to the moveable component and provides the only connection between the FPC and the moveable component. At least part of the connecting portion may lie in the same plane at least one of the fold lines of the FPC.
An advantage of a single connecting portion providing a connection to the support structure or the moveable component is that compliance of the FPC in a direction perpendicular to the fold lines may be increased (as compared to an FPC with a greater number of connecting portions).
According to another aspect of the present disclosure, there is provided an actuator assembly comprising: a support structure; - a moveable component which is moveable relative to the support structure and a flexible printed circuit, FPC, which is folded along two or more fold lines.
The FPC provides an electrical connection between the moveable component and the support structure and comprises a connecting portion connected to one of the support structure and moveable component. At least part of the connecting portion lies in the same plane as at least one of the fold lines of the FPC. Additionally, either: - all of the lines along which the FPC is folded lie in a plane; or each of the lines along which the FPC is folded lie in one of a plurality of planes, wherein the plurality of planes are parallel to eachother.
In some embodiments, the FPC may comprise a first planar portion and a second planar portion. The first planar portion is substantially perpendicular to the second planar portion and the first and second portions are both substantially perpendicular to a plane in which at least one of the fold lines lie. This has advantaged as described above with reference to the method of manufacture.
In some embodiments, the moveable component may comprise a display panel, an illumination source or an image sensor assembly comprising an image sensor having a light-sensitive region..
In some embodiments, the folded FPC may comprise: (a) a portion which is perpendicular to a plane in which at least one of the fold lines lie and (b) a portion which is coplanar with a plane in which at least one of the fold lines lie.
The portion which is parallel to a plane in which at least one of the fold lines lie may comprise a greater number of layers of conductive tracks than the portion which is perpendicular to a plane in which at least one of the fold lines lie.
In some embodiments the FPC may extend in a loop around the movable component.
In some embodiments the FPC comprises first, second, third and fourth sides, wherein the first side is opposite the third side and the second side is opposite the fourth side. The moveable component is connected to the FPC on its first side and the support structure is connected to the FPC on its third side. Therefore, the moving and static ends of the FPC are on opposing sides. This allows the flexible length of the FPC arms to be increased therefore allowing a reduction in stiffness of the structure.
In some embodiments, the FPC may comprise first, second, third and fourth sides and the moveable component is connected to the FPC on its first side and the support structure is connected to the FPC on its second side, which is adjacent to the first side.
In some embodiments, the FPC may comprise at least one fold line on each of its sides (e.g. four sides).
Optionally, any of the actuator assemblies described herein may comprise one or more shape memory alloy, SMA, wires configured to move the moveable component.
Any of the features described herein with reference to one embodiment may be applied to other embodiments. Equally, any definitions made in the context of one embodiment may also apply to other embodiments.
Herein, reference to two elements lying in the same plane or being coplanar is intended to refer to at least an overlap of the elements in a direction perpendicular to the plane.
Herein, reference to connection of a component or element of a device to the support structure of the device is intended to include connection to a second component or element of a device which remains stationary relative to the support structure during use of the device.
Brief description of the drawings
CO Certain embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which: CO Figure 1A is a schematic view of an interconnect arrangement in a flat form, prior to folding; 04120 Figure 1B is a schematic view of the interconnect arrangement of figure 1A in a folded form; Figure 2 is a schematic view of an alternative interconnect arrangement in a flat form, prior to folding; Figure 3A is a schematic view an alternative interconnect arrangement in a flat form, prior to folding; Figure 3B is a schematic view of the interconnect arrangement of figure 3A in a folded form; Figure 4A is a schematic view of an alternative interconnect arrangement in a flat form, prior to folding; Figure 4B is a schematic view of the interconnect arrangement of figure 4A in a folded form; Figure.5A is a schematic view of an alternative interconnect arrangement in a flat form, prior to folding; Figure 5B is a schematic view of the interconnect arrangement of figure 5A in a folded form; and Figure.5C is a different view of the interconnect arrangement of figure 5B.
Detailed description
Figure 1A illustrates an FPC 2, which, as shown in Figure 1A, is a flat sheet. The FPC 2 has conventional construction and comprises a flexible substrate made of a suitable material, for example a plastic such as polyimide, PEEK or polyester and conductive (e.g. copper) tracks. During manufacture, the FPC 2 is folded along fold lines 4, 6, 8 and 10.
S
Figure 1B illustrates the FPC 2 of figure lA in its folded form, which is the result of folding the flat sheet shown in Figure 1A along fold lines 4, 6, 8 and 10. The FPC 2 comprises a central portion 12 and first and second arms 14 and 16. The central portion 12 comprises a first connecting portion 18 which is for attachment to a non-moving component of the device in which the FPC 2 is disposed. For example, the first connecting portion 18 may, in use, be attached to a support structure of a device, for example of a camera.
The first and second arms 14 and 16 each comprise a respective second connecting portion (24 and 26 respectively). The second connecting portions are for attachment to a moving component of the device in which the FPC 2 is disposed. For example, the moving component may be an image sensor of a camera.
The first and second arms 14 and 16 are each separated from the central portion 12 by respective bend portions (20 and 22 respectively). The bend portions 20 and 22 each facilitate a bend through 90 degrees but it will be appreciated that different angles may be used instead (i.e. there may be a different angle between the arms 14 and 16 and the central portion 12). The angle between the central portion 12 and the arms 14 and 16 facilitate compliance of the FPC 2 in a first direction and a second direction which is perpendicular to the first direction (x and y, as labelled in Figure 1B). Accordingly, this means that the FPC 2 accommodates motion of the moving component (e.g. an image sensor) along the x and y axes.
Further, the FPC 2 also accommodates motion of the moving component along a third direction which is perpendicular to the first and second directions (i.e. the z direction, perpendicular to x and y as labelled in Figure 13). This is facilitated by the single connecting portion 18 which connects the FPC 2 to the non-moving component of the device, e.g. the support structure. Compliance in this third direction is also facilitated by other portions of the FPC which lie in the same plane (e.g. bend portions 20 and 22), It will be appreciated that the connections of the moving and non-moving components could be swapped in some embodiments (i.e. the first connection portion 18 may be attached to the moving component and the second connection portions 24 and 26 may be attached to the non-moving component).
Various portions of the FPC may have differing numbers of layers of conductive tracks. In the embodiment shown in Figure 1B, some portions are perpendicular to the original plane in which the FPC was initially formed. These portions may comprise two layers of tracks whereas the portions of the FPC which are parallel to the original plane comprise 4 layers By using 4 layers in these portions, the footprint (in the original plane, i.e. the x-y plane) may be reduced. Two layers may be used in the portions which are perpendicular to the original plane (i.e. the x-y plane in Figure 1B) to increase compliance of these portions.
In some embodiments, the FPC may comprises a single arm (as opposed to the two in the Figures 1A and 18 embodiment). Such an embodiment is shown in Figure 2 in its flat form, before folding. Only the differences as compared with the embodiment shown in Figures 1A and 1B are shown here and like reference numerals are used for like parts.
With reference to Figure 2, during manufacture, the FPC 2 is folded along fold lines 4,6 and 8. The FPC 2 comprises a single arm 14 separated from the central portion 12 by a bend 20. In this embodiment, all portions of the FPC 2 may comprise four layers of tracks. This may increase stiffness (as compared to a 2-layer construction) but the length of the arm 14 could be increased to compensate for this.
In some embodiments, the moving and non-moving components may be on opposite sides of the FPC (as compared with the embodiments in Figures 1A, 1B and 2 in which the moving and non-moving components are connected to adjacent sides of the FPC). With reference to Figures 3A and 38, an FPC 2 is illustrated. Only the differences as compared with the embodiment shown in Figures 1A and 1I3 are shown here and like reference numerals are used for like parts. In addition to first and second arms 14 and 16, the FPC 2 also comprises a third arm 28, which is connected to both the first and second arms and by bend portions 30 and 32 respectively. The third arm 28 comprises a third connecting portion 34 for attachment to the moving component, for example an image sensor. This third connecting portion 34 replaces the second connection portions shown in Figures 1A and 1B but it will be appreciated than any number of such connection portions may be provided.
The entire FPC may comprise 4 layers of conductive tracks. This may reduce the height of the FPC (as compared to the use of e.g. 2 layers). The increased length of the arms of this embodiment of the FPC (compared to previous embodiments) may enable 4 layers to be used without making a significant impact on flexibility of the FPC.
With reference to Figures 44 and 48, a further embodiment of an FPC 2 is described. This embodiment shares a number of features with that shown in Figures 3A and 38 and only the differences will be described here. Like reference numerals are used for like parts. Figure 44 shows the FPC 2 in its flat form, prior to folding. The embodiment shown in Figure 4A is for connecting an image sensor to a support structure of a camera or device on which a camera is disposed (e.g. a smartphone). Also shown in Figure 4A is the PCB of the image sensor. The FPC 2 is folded along fold lines 4, 6, 8 and 10.
Figure 4B shows the FPC 2 in its folded state, produced by folding the flat FPC 2 shown in Figure 4A along fold lines 4, 6, 8 and 10. Figure 4B additionally shows an image sensor bracket 38 for holding the image sensor. As shown in Figure 4B, the first connecting portion 18, which is for connection to a support structure of the device, lies in a plane which is parallel to, but displaced from (in a direction perpendicular to the plane of the original, flat FPC), the plane of the original, flat FPC. This configuration is achieved by folding FPC 2 along fold line 8A. The extra length provided by this configuration of the connecting portion 18 (as compared to the embodiment shown in Figure 3B, for example) provides for increased compliance of the FPC.
With reference to Figures 5A, 5B and 5C, a further embodiment of an FPC 2 is described. This embodiment shares a number of features with that shown in Figures 4A and 4B and only the differences will be described here. Like reference numerals are used for like parts. Figure 5A shows the FPC 2 in its flat form. In this embodiment, the actuator assembly comprises PCBs 40 and 42 which provide connections to other components of the device. Such PCBs may be integral with and form part of the FPC 2. During manufacture, as the FPC 2 is folded into its folded form (shown in Figures 5B and 5C), the PCBs 40 and 42 move with the FPC and then are attached to other components of the device which remain fixed relative to the support structure of the device.
With reference to Figure 6, a method of manufacturing a device is described. At step 44, a flat FPC is folded along two or more fold lines. This may be done using a single tool and/or in a single step. For example, such a flat FPC is illustrated in Figure 4A and this FPC is folded along fold lines 4, 6, 8, and 10.
At step 46, the folded FPC is electrically connected to both a moveable component of a device, which moves relative to a support structure of the device, and the support structure. Such a method may be used to manufacture any of the FPCs shown in the Figures. As mentioned above, all of the fold lines may be in the same plane, e.g. the plane defined by the flat FPC, at the time the folds are made.
As used herein, the term 'substantially' equal may refer to two values being within e.g. 10% or 5% of eachother.
Any FPC or portion of FPC disclosed herein may comprise any number of layers, for example one, two, three, four, five or more.
Instead of being flexible printed circuits per se, the FPCs described herein may correspond to other types of flexible electrical connectors, e.g. connectors made using techniques other than photolithographic techniques, connectors with metallic substrates, etc. The electrical interconnects described herein may be used with various actuator types. For example, actuation may be achieved using shape memory alloy (SMA) wire, voice coil motors, piezoelectric actuators, ultrasonic motors, and/or microelectromechanical systems (MEMS).
Some of the above-described actuators are SMA actuator assemblies which comprise an SMA wire. The term 'shape memory alloy (SMA) wire' may refer to any element comprising SMA. The SMA wire may have any shape that is suitable for the purposes described herein. The SMA wire may be elongate and may have a round cross section or any other shape cross section. The cross section may vary along the length of the SMA wire. It is also possible that the length of the SMA wire (however defined) may be similar to one or more of its other dimensions. The SMA wire may be pliant or, in other words, flexible.
In some examples, when connected in a straight line between two elements, the SMA wire can apply only a tensile force which urges the two elements together. In other examples, the SMA wire may be bent around an element and can apply a force to the element as the SMA wire tends to straighten under tension. The SMA wire may be beam-like or rigid and may be able to apply different (e.g. non-tensile) forces to elements. The SMA wire may or may not include material(s) and/or component(s) that are not SMA. For example, the SMA wire may comprise a core of SMA and a coating of non-SMA material.
Unless the context requires otherwise, the term 'SMA wire' may refer to any configuration of SMA wire acting as a single actuating element which, for example, can be individually controlled to produce a force on an element. For example, the SMA wire may comprise two or more portions of SMA wire that are arranged mechanically in parallel and/or in series. In some arrangements, the SMA wire may be part of a larger piece of SMA wire. Such a larger piece of SMA wire might comprise two or more parts that are individually controllable, thereby forming two or more SMA wires.
Applications Although many of the above examples relate to use of the disclosed actuator assemblies in a camera, the actuator assemblies may equally be used in any application in which a movable electronic component must be moved relative to a static component. For example, the actuator assemblies could be used to connect an illumination source that is moved, for example for the purposes of 3D scanning.
It will be appreciated that there may be many other variations of the above-described examples.

Claims (25)

  1. Claims 1. A method of manufacturing a device, the method comprising: folding a flat flexible printed circuit, FPC, which defines a first plane, along two or more fold lines, wherein all of the lines along which the FPC is folded lie in the first plane; and electrically connecting the folded FPC between a moveable component of the device and a support structure of the device, wherein the moveable component is moveable relative to the support structure.
  2. 2. A method according to any preceding claim, wherein the folded FPC is configured to allow movement of the moveable component relative to the support structure along two perpendicular axes and/or rotation of the moveable component about an axis.
  3. 3. A method according to any preceding claim, wherein the folded FPC is configured to allow movement of the moveable component relative to the support structure along three perpendicular axes.
  4. 4. A method according to claim 1, wherein the folded FPC is configured to allow tilting of the moveable component relative to the support structure about two perpendicular axes.
  5. 5. A method according to any preceding claim, wherein the folded FPC comprises a first planar portion and a second planar portion, wherein the first planar portion is substantially perpendicular to the second planar portion and the first and second portions are both substantially perpendicular to the first plane.
  6. 6. A method according to any preceding claim, wherein the moveable component comprises a display panel, an illumination source or an image sensor assembly comprising an image sensor having a light-sensitive region
  7. 7. A method according to any preceding claim, wherein the folded FPC comprises: (a) a portion which is perpendicular to the first plane; and (b) a portion which lies in the first plane, wherein the FPC comprises a greater number of layers of conductive tracks over at least some of the portion which lies in the first plane than over at least some of the portion which is perpendicular to the first plane.
  8. 8. A method according to any preceding claim, wherein the FPC extends in a loop around the movable component.
  9. 9. A method according to claim 8, wherein the FPC comprises first, second, third and fourth sides, wherein the first side is opposite the third side and the second side is opposite the fourth side and wherein the method comprises connecting the moveable component to the folded FPC on its first side and the support structure to the folded FPC on its third side.
  10. 10. A method according to claim 8, wherein the FPC comprises first, second, third and fourth sides and wherein the method comprises connecting the moveable component to the FPC on the first side and the support structure to the FPC on its second side, which is adjacent to the first side.
  11. 11. An actuator assembly comprising: a support structure; a moveable component which is moveable relative to the support structure along three perpendicular axes; and a flexible printed circuit, FPC, which provides an electrical connection between the moveable component and the support structure, wherein the FPC is folded along two or more fold lines and wherein the FPC is configured to allow movement of the moveable component relative to the support structure along the three perpendicular axes; wherein: all of the lines along which the FPC is folded lie in a plane; or each of the lines along which the FPC is folded lie in one of a plurality of planes, wherein the plurality of planes are parallel to eachother.
  12. 12. An actuator assembly comprising: a support structure; a moveable component which is moveable relative to the support structure; and a flexible printed circuit, FPC, which provides an electrical connection between the moveable component and the support structure, wherein the FPC is folded along two or more fold lines and wherein the FPC is configured to allow tilting of the moveable component relative to the support structure about two perpendicular axes; wherein: all of the lines along which the FPC is folded lie in a plane; or each of the lines along which the FPC is folded lie in one of a plurality of planes, wherein the plurality of planes are parallel to eachother.
  13. 13. An actuator assembly comprising: a support structure; a moveable component which is moveable relative to the support structure; and a flexible printed circuit, FPC, which provides an electrical connection between the moveable component and the support structure, wherein the FPC is folded along two or more fold lines and wherein the FPC is configured to allow rotation of the moveable component relative to the support structure about an axis of rotation; wherein: all of the lines along which the FPC is folded lie in a plane; or each of the lines along which the FPC is folded lie in one of a plurality of planes, wherein the plurality of planes are parallel to eachother.
  14. 14. An actuator assembly according to any of claims 11 to 13 wherein the FPC comprises a connecting portion connected to one of the support structure and moveable component, wherein at least part of the connecting portion lies in the same plane at least one of the fold lines of the FPC.
  15. 15. An actuator assembly according to claim 14, wherein the connecting portion is connected to the support structure and provides the only connection between the FPC and the support structure or wherein the connecting portion is connected to the moveable component and provides the only connection between the FPC and the moveable component.
  16. 16. An actuator assembly according to claim 15, wherein the FPC further comprises a further connecting portion which is connected to the moveable component and provides the only connection between the FPC and the moveable component.
  17. 17. An actuator assembly comprising: a support structure; a moveable component which is moveable relative to the support structure; and a flexible printed circuit, FPC, which is folded along two or more fold lines and which provides an electrical connection between the moveable component and the support structure and which comprises a connecting portion connected to one of the support structure and moveable component, wherein at least part of the connecting portion lies in the same plane as at least one of the fold lines of the FPC; wherein: all of the lines along which the FPC is folded lie in a plane; or each of the lines along which the FPC is folded lie in one of a plurality of planes, wherein the plurality of planes are parallel to eachother.
  18. 18. An actuator assembly according to any of claims 11 to 17, wherein the FPC comprises a first planar portion and a second planar portion, wherein the first planar portion is substantially perpendicular to the second planar portion and the first and second portions are both substantially perpendicular to a plane in which at least one of the fold lines lie.
  19. 19. An actuator assembly according to any of claims 11 to 18, wherein the moveable component comprises a display panel, an illumination source or an image sensor assembly comprising an image sensor having a light-sensitive region.
  20. 20. An actuator assembly according to any of claims 11 to 19, wherein the FPC comprises: (a) a portion which is perpendicular to a plane in which at least one of the fold lines lie and (b) a portion which is coplanar with a plane in which at least one of the fold lines lie, wherein the portion which is parallel to a plane in which at least one of the fold lines lie comprises a greater number of layers of conductive tracks than the portion which is perpendicular to a plane in which at least one of the fold lines lie.
  21. 21. An actuator assembly according to any of claims 11 to 20, wherein the FPC extends in a loop around the movable component.
  22. 22. An actuator assembly according to claim 21, wherein the FPC comprises first, second, third and fourth sides, wherein the first side is opposite the third side and the second side is opposite the fourth side, wherein the moveable component is attached to the FPC on its first side and the support structure is connected to the FPC on its third side.
  23. 23. An actuator assembly according to claim 21, wherein the FPC comprises first, second, third and fourth sides and wherein the moveable component is connected to the FPC on the first side and the support structure to the FPC on its second side, which is adjacent to the first side.
  24. 24. An actuator assembly according to claim 17, wherein the connecting portion is connected to the support structure and provides the only connection between the FPC and the support structure and optionally wherein the FPC further comprises a further connecting portion which is connected to the moveable component and provides the only connection between the FPC and the moveable component.
  25. 25. An actuator assembly according to claim 17, wherein the connecting portion is connected to the moveable component and provides the only connection between the FPC and the moveable component and optionally wherein the FPC further comprises a further connecting portion which is connected to the support structure and provides the only connection between the FPC and the support structure.
GB2202988.8A 2022-03-03 2022-03-03 Electrical interconnect and method of manufacture Pending GB2616416A (en)

Priority Applications (1)

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Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
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GB2616416A true GB2616416A (en) 2023-09-13

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170336019A1 (en) * 2016-05-17 2017-11-23 ZEROTECH (Shenzhen) Intelligence Robot Co., Ltd. Gimbal and method for winding flexible cable on gimbal
US20210084203A1 (en) * 2019-09-18 2021-03-18 New Shicoh Motor Co., Ltd Actuator, Camera Module and Camera Mounting Device
US20210092297A1 (en) * 2019-09-25 2021-03-25 Apple Inc. Dynamic Flex Circuit for Camera With Moveable Image Sensor

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170336019A1 (en) * 2016-05-17 2017-11-23 ZEROTECH (Shenzhen) Intelligence Robot Co., Ltd. Gimbal and method for winding flexible cable on gimbal
US20210084203A1 (en) * 2019-09-18 2021-03-18 New Shicoh Motor Co., Ltd Actuator, Camera Module and Camera Mounting Device
US20210092297A1 (en) * 2019-09-25 2021-03-25 Apple Inc. Dynamic Flex Circuit for Camera With Moveable Image Sensor

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