Double-sided flexible circuit assembly and method of manufacture therefor

Claim 3

A method of fabricating a double-sided circuit assembly in accordance with claim 1, wherein in forming said first set of terminals, each terminal thereof is positioned in mutually aligned relationship with a different terminal of the second set, and wherein in permanently securing said substrate to said support member, at least that portion of the second side of said substrate in contact with said support member is bonded thereto.

Claim 4

A method of fabricating a double-sided circuit assembly in accordance with claim 1, wherein in interConnecting said second set of terminals to said second circuit pattern on the opposite side of said substrate, plated-through holes are formed.

Claim 5

A method of fabricating a double-sided circuit assembly in accordance with claim 3, further including the step of plating at least the terminals of said first and second sets with a layer of precious metal.

Claim 6

A method of fabricating a double-sided circuit assembly in accordance with claim 4, further including the step of forming beveled corners on the terminal support member along the edge thereof about which a portion of the flexible substrate is bent so as to facilitate the insertion of the terminal end of the double-sided circuit in a female-type connector.

Claim 7

A method of fabricating a double-sided circuit assembly in accordance with claim 4, further including the step of forming tapered regions on opposite sides of the terminal support member, said tapered regions being mutually disposed and oriented in a direction so as to provide a predetermined thickness dimension at the terminal supporting end of the support member which is compatible with a given external female-type connector, said tapered regions also functioning as positive stops when contacted by outwardly extending nose portions of an external connector.

Claim 8

A double-sided electrical circuit assembly comprising: a thin, flexible non-conductive substrate; a first conductive circuit pattern of predetermined configuration formed on a first side of said substrate; a second conductive circuit pattern of predetermined configuration formed on the second side of said substrate; a relatively rigid support member having a top surface area, an edge surface area and a bottom surface area secured to at least a portion of the second side of said substrate upon the latter being bent around said support member in a U-shaped manner; a first set of terminals formed on said first side of said substrate and electrically connected to said first circuit pattern, said first set of terminals being inset a predetermined distance from one edge of said substrate; a second set of terminals formed on the first side of said substrate and connected to said second circuit pattern on the opposite side of said substrate by means of through-hole connections, said second set of terminals being interposed between said first set of terminals and the adjacent common edge of said substrate so as to define a longitudinally extending fold-back space of predetermined width between said first and second sets of terminals, said substrate being folded back, along said longitudinally extending space, around the edge surface area of said support member and secured to the top and bottom surfaces thereof so as to position permanently said first and second sets of terminals in mutually disposed, overlying relationship on opposite sides of said support member.

Claim 9

A double-sided electrical circuit assembly comprising: a thin, flexible non-conductive substrate; a first conductive circuit pattern of predetermined configuration formed on a first side of said substrate; a second conductive circuit pattern of predetermined configuration formed on the second side of said substrate; a relatively rigid support member having a top surface area, an edge surface area and a bottom surface area secured to at least a portion of the second side of said substrate upon the latter being bent around said support member in a U-shaped manner; a first set of terminals formed on said first side of said substrate and electrically connected to said first circuit pattern, said first set of terminals being inset a predetermined distance from one edge of said substrate; a second set of terminals formed on the first side of said substrate and connected to said second circuit pattern on the opposite side of said substrate by means of through-hole connections, said second set of terminals being interposed between said first set of terminals and the adjacent common edge of said substrate so as to define a longitudinally extending fold-back space of predetermined width between said first and second sets of terminals, said substrate being folded back, along said longitudinally extending space, around the edge surface area of said support member and secured to the top and bottom surfaces thereof so as to position permanently said first and second sets of terminals in mutually disposed, overlying relationship on opposite sides of said support member.

Claim 10

A double-sided circuit assembly in accordance with claim 7, wherein each terminal of said first set is positioned in mutually aligned relationship with a different terminal of the second set, and wherein at least that portion of the second side of said substrate in contact with said support member is bonded thereto.

Claim 11

A double-sided circuit assembly in accordance with claim 7, wherein said second set of terminals is electrically connected to said second circuit pattern on the opposite side of said substrate by plated through-holes.

Claim 12

A double-sided electrical circuit assembly in accordance with claim 9, wherein the terminals of said first and second sets are formed as rectangularly shaped tabs so as to be readily accessed by mating contacts of female type connectors, and wherein said terminals are formed with a base layer of copper and have a thin overlying layer of precious metal deposited thereon.

Claim 13

A double-sided circuit assembly in accordance with claim 9, wherein the edge surface area of said terminal support member is formed with beveled corners so as to facilitate the insertion of said first And second sets of terminals within a female-type connector.

Claim 14

A double-sided circuit assembly in accordance with claim 9, wherein said terminal support member is formed with at least two mutually disposed tapered regions, said regions being formed inwardly of said terminals and oriented toward each other in the direction of said terminals so as to provide said support member with both a terminal supporting thickness dimension compatible for use with a given female-type connector, and positive stops for outwardly extending nose portions of a connector when brought into contact therewith.