Electronic device comprising a flexible printed circuit board
The invention relates to an electronic device comprising a flexible printed circuit board having an electrically conductive layer on one side of the flexible board, and a conductive metallic stiffener which is attached to the flexible board, wherein said conductive layer is conductively connected to the metallic stiffener by means of solder. To this end, the metallic stiffener must be made of a solderable material or coated with such a material.
In order to reduce bending and other deformations of the flexible printed circuit board (hereinafter referred to as flexible board), the metallic stiffener is attached to the surface of the flexible board, or to a portion of this surface, by means of an adhesive layer which is present between the flexible board and the metallic stiffener. In some applications, it may be desirable to provide an electrically conductive connection between the metallic Stiffener and the conductive layer on the flexible board.
US-A-6,534,848 describes several manners of coupling a flexible board (substrate) to a metallic stiffener which is conductively connected to the electrically conductive layer on the flexible board. The conductive layer on the flexible board faces the metallic stiffener and an adhesive layer is present in between. A hole in the adhesive layer comprises a volume of solder, so that an electrically conductive connection between the metallic stiffener and the conductive layer is achieved. Although a reliable conductive connection can be obtained, the described structure has some disadvantages.
In order to provide an appropriate reflow of the solder, there must be one proper heat treatment of both the solder and the adhesive layer, so that the adhesive material cures, and at the same time the solder reflows correctly. For this reason, an appropriate adhesive material as well as a specific treatment must be applied. Furthermore, in order to apply the known method of connecting the flexible board to the metallic stiffener, the conductive layer must be located at the side of the flexible board where the metallic stiffener is present. Consequently, the known method can only be applied in certain structures. Moreover, after the conductive connection has been made by means of the solder, the solder
cannot be removed in order to disconnect the conductive layer from the metallic stiffener, for example, for testing purposes.
It is an object of the invention to provide an electronic device, wherein the electrically conductive layer of the flexible printed circuit board is electrically connected to the metallic stiffener to which the flexible board is attached, and wherein one or more of the above disadvantages are avoided.
It is another object of the invention to provide an electronic device, wherein a standard reflow solder process can be applied to connect the stiffener with the electrically conductive layer of the flexible printed circuit board.
To achieve this object, the flexible board is provided with a through-hole in which the solder connecting the metallic stiffener with the conductive layer is present and through which the solder can be applied. The connection by means of the solder can be applied when the flexible board is already attached to the metallic stiffener. After the flexible board and the metallic stiffener have been attached to each other by means of the usual method and the usual adhesive material, the solder can be applied in the through-hole, and a reliable reflow of the solder can take place within a short time. Of course, a part of the surface of the conductive layer must be accessible for the solder. If the conductive layer faces the metallic stiffener, a portion of the surface of the conductive layer near the through-hole must therefore be free from the adhesive material.
In a preferred embodiment, said conductive layer is present on the side of the flexible board facing away from the metallic stiffener. Such a structure is not possible when applying the method according to US-A-6,534,848. However, depending on the design of the electronic device, such a structure may be required. Another advantage is the possibility of visible inspection of the connection between the solder and the conductive layer.
The flexible printed circuit board is preferably a single-sided board having only one electrically conductive layer at the side facing away from the metallic stiffener. When using the metallic stiffener for high-frequency grounding, a single-sided flexible board can sometimes be used where a dual or multilayer design would be required.
In another preferred embodiment, the conductive layer is covered by a cover layer, wherein the hole in the cover layer has a larger diameter than the corresponding hole in the conductive layer. A portion of the surface of the conductive layer around the edge of the hole is available for connection with the solder.
The hole in the material of the flexible board preferably has a larger diameter than the corresponding hole in the conductive layer. By etching away a portion of the substrate material around the through-hole underneath the conductive layer, a part of the lower surface of the conductive layer is available for connection with the solder. In some designs, only one through-hole is sufficient to connect the conductive layer to the metallic stiffener. In more complex designs, it is preferred that a plurality of through-holes is present in the flexible board in order to connect different parts of the conductive layer with the metallic stiffener. In this way, the different parts of the conductive layer can be interconnected through the metallic stiffener. The invention also relates to a method of attaching a flexible printed circuit board having an electrically conductive layer on one side of the flexible board to a conductive metallic stiffener, wherein solder is applied to conductively connect said conductive layer to the metallic stiffener, and the flexible board is provided with a through- hole, the solder for connecting the metallic stiffener with the conductive layer being applied in said through-hole after the flexible board has been attached to the metallic stiffener.
The invention will now be further elucidated by means of a description of an embodiment of the device according to the invention, having a structure comprising a flexible printed circuit board with an electrically conductive layer on one side of the flexible board and comprising a conductive metallic stiffener which is attached to the flexible printed circuit board.
In the drawing,
Fig. 1 is a sectional view of a portion of the structure; and Fig. 2 is a sectional view taken on the line II-II in Figure 1.
The Figures are schematic representations showing only the mutual relation of relevant parts of the structure. Figure 1 shows a portion of a flexible plate-like substrate (layer 1 of an insulating material) comprising a layer 2 of electrically conductive material, for example, copper at one side (the upper side). The layer 2 of conductive material is covered by a cover layer 3 of an insulating material. These three layers 1,2,3 jointly form a single-sided flexible printed circuit board, a part of which is shown in Figures 1 and 2. Before the cover layer 3 is
applied on the flexible board, portions of the layer 2 of conductive material are etched away in order to create a certain pattern of the conductive material on the substrate 1.
Figure 2 is a sectional view taken on the line H-II, i.e. along a plane through the layer 2 of conductive material. The conductive material in Figure 2 is indicated by the shaded area, showing an outer area 4, an inner area 5, and two parallel conductive paths 6,7, located between the outer area 4 and the inner area 5. Around area 4 and between the areas 4,5 and the parallel conductive paths 6,7, there is insulating material of the cover layer 3, which material is not shaded in Figure 2, although it is shown in a sectional view.
Figure 1 further shows a portion of a metallic stiffener 8, which is a rather thick metal plate. At least a part of the flexible board 1,2,3 is attached to the stiffener 8 by means of a layer 9 of adhesive material shown as a fat, solid line in Figure 1. The stiffener 8 supports the flexible board 1,2,3 and reduces bending and other deformations of the flexible board.
A flexible printed circuit board may have a plurality of layers of conductive material, mutually separated by insulating layers, or only one layer 2 of conductive material as shown in the described structure. The one or more conductive layers 2 comprise conductive paths 6,7 for electrically connecting electronic components such as chips, which may be attached to the flexible board. The conductive layer 2 may also comprise conductive areas 4,5, for example, for shielding purposes. If a connection between the two conductive areas 4,5 is required, while the conductive areas 4,5 are separated by one or more conductive paths 6,7, an electrically conductive link outside the conductive layer 2 is required. Of course, such a conductive link can be established in an additional layer of conductive material on the flexible board. However, in the described structure, such a conductive link is established through the metallic stiffener 8, so that an additional conductive layer is not required.
In order to electrically connect the material of conductive area 4 with the material of the stiffener 8, the flexible board 1,2,3 is provided with a through-hole 10 at such a location that the conductive material of layer 2 is present on the inner surface of the through-hole 10. After the flexible board 1,2,3 has been attached to the stiffener 8 by means of the adhesive layer 9, the through-hole can be filled with solder which reflows in such a way that it makes contact with the surface of the stiffener 8 as well as with the material of area 4 of the conductive layer 2. Of course, the surface of the stiffener 8 at the location of the through-hole 10 must be clean and free from adhesive material in order to ensure an appropriate electric connection between the stiffener 8 and the solder.
In order to ensure an appropriate electric contact between the conductive material of layer 2 and the solder, the diameter of the through-hole in the cover layer 3 and/or the diameter of the through-hole in the substrate 1 can be made larger than that of the through-hole in the conductive material of layer 2, as is shown in Figure 1. More surface of the conductive material of layer 2 is then available for contacting the solder during the reflow process.
The through-hole 10 in Figure 1 is located in area 4 of the conductive layer 2 and electrically connects area 4 of the conductive material 2 with the material of the metallic stiffener 8. Area 4 can be electrically connected to area 5 of the conductive layer 2 through metallic stiffener 8 by providing a conductive connection between the metallic stiffener 8 and area 5. Such a conductive connection can be made by means of another through-hole 11 (see Figure 2), similar to through-hole 10. It will be clear that the metallic stiffener 8 functions as a conductive bridge between the two areas 4,5 of layer 2.
The embodiment of the electronic device as described above is only an example; a great many other embodiments are possible. For example, there may be only one through-hole for connecting one location of the conductive layer 2 with the metallic stiffener 8. The presence of an insulating cover layer 3 is not always required. There may also be more than one conductive layer in the flexible printed circuit board, with only one or even more conductive layers being conductively connected with the stiffener.