Self-soldering flexible circuit connector

Claim 2

In combination a flexible circuit having at least one conductor disposed in and surrounded by insulating material covering said conductor, said material having large opposed surfaces, a heater disposed along and in contact with one of said surfaces to heat a limited region of said conductor, said at least one conductor having the insulating material removed along the other of said opposed surfaces opposite the limited region of said conductor to be heated, said heater including means for connection to a source of energy.

Claim 3

A combination according to claim 1 wherein said opposed surface of said conductor is contacted with by solder.

Claim 4

A combination according to claim 2 wherein said flexible circuit has a plurality of conductors have limited regions and at least several of said conductors exposed in a predetermined array overlying said heater.

Claim 5

A combination according to claim 3 further including a solder reflow pad of insulating material overlying exposed regions of said conductors, said solder reflow pad having solder filled windows in alignment with said exposed limited regions.

Claim 6

A combination according to claim 4 wherein said reflow pad has a compliant insulating layer generally coextensive with said pad.

Claim 7

A combination according to claim 3 wherein said heater is a heater that upon application of a constant alternating current is temperature self regulating.

Claim 8

A combination according to claim 2 or claim 6 wherein said heater is enclosed between one part of said flexible circuit and a folded over part of said flexible circuit.

Claim 9

A combination according to claim 1 wherein said heater is of the order of 0.030 inch thick.

Claim 10

A combination according to claim 3 or claim 6 further including an electrical circuit having a pattern of exposed conductors generally a same as the pattern of limited exposed regions of said conductors region of said flexible circuit, and means for aligning said patterns of conductors.

Claim 11

A combination according to claim 9 further comprising a plurality of said electric circuits, said flexible circuit having a plurality of limited regions of exposed surfaces of said conductors, and means for engaging each of said regions of exposed conductors with a different one of said limited electrical circuits.

Claim 12

A combination according to claim 3 or claim 6 further comprising an electrical connector having a plurality of alternating layers of insulating material and conductive material, said limited regions of exposed conductors of said flexible circuit having a spacing and pattern corresponding to said conductive layers, and means for placing said limited regions of exposed conductors in alignment and contact with said layers of conductive material.

Claim 13

A combination according to claim 3 or claim 6 further comprising a printed circuit board having an array of exposed contacts conforming generally to the geometry of the array overlying said heater, a clothes-pin like member having a pair of elongated legs terminating at one end in opposed jaws having a pair of pins located adjacent the two ends of one of said jaws and extending toward the other of said jaws, said flexible circuit secured to a surface of one of said elongated legs facing the other of said legs, registration holes in said flexible circuit and said printed circuit board arranged such that when said holes are aligned said arrays are aligned with said pins positioned to pass through said holes upon alignment.

Claim 14

A connection arrangement comprising a flexible circuit having a plurality of flexible conductors disposed in and surrounded by flexible insulating material covering said conductors. said insulating material having large opposed surfaces, a heater disposed along and in contact with one of said surfaces to heat a limited region of some of said conductors, some of said conductors having the insulating material removed along the other of said opposed surfaces to expose said limited region of some of said conductors in a specific array, said heater including means for connection to a source of energy, said heater fixed in position relative to said flexible circuit to heat said limited regions, a connector having an opening permitting insertion of an electrical circuit between and in contact with said limited region of at least one of said conductors, and means causing terminals on the electrical circuit to be aligned with said at least limited region of at least one of the exposed conductors of said flexible circuit.

Claim 15

A connection arrangement comprising a flexible circuit having a plurality of flexible conductors disposed in and surrounded by flexible insulating material covering said conductors. said insulating material having large opposed surfaces, a heater disposed along and in contact with one of said surfaces to heat a limited region of some of said conductors, some of said conductors having the insulating material removed along the other of said opposed surfaces to expose said limited region of some of said conductors in a specific array, said heater including means for connection to a source of energy, said heater fixed in position relative to said flexible circuit to heat said limited regions, a connector having an opening permitting insertion of an electrical circuit between and in contact with said limited region of at least one of said conductors, and means causing terminals on the electrical circuit to be aligned with said at least limited region of at least one of the exposed conductors of said flexible circuit.

Claim 16

A connection arrangement according to claim 13 wherein a limited region of exposed conductor is adapted to be aligned with conductors of a further electrical circuit.

Claim 17

A connection arrangement according to claim 14 further comprising a third limited region of exposed conductors on said flexible circuit, and a heater associated with said third region of exposed conductors.

Claim 18

A connection arrangement according to claim 15 wherein said third region lies along the base of the U-shaped connector.

Claim 19

A connection arrangement according to claim 13 further comprising a third limited region of exposed conductors on said flexible circuit.

Claim 20

A connection arrangement according to claim 17 wherein said third limited region of exposed conductors are adapted to be aligned with further conductors of the first-mentioned electrical circuit.

Claim 21

A connection arrangement according to claim 18 wherein said connector is U-shaped and wherein one of said limited regions of exposed conductors lies along one of the legs of said U-shaped connector.

Claim 22

A connection arrangement according to claim 18 wherein the second limited region of exposed conductors lies along the other leg of said U-shaped connector.

Claim 23

A connection arrangement according to claim 13, comprising a spring, said limited region of at least one of said conductors disposed in alignment with and spaced from said spring, and means permitting insertion of an electrical circuit between said limited region of exposed conductors and said such that said spring biases said electrical circuit into contact with said at least one limited region of exposed conductors, and means for providing alignment between exposed conductors of said flexible circuit with exposed conductors of the electrical circuit.

Claim 24

A connection arrangement comprising a flexible circuit having a plurality of flexible conductors disposed in and surrounded by flexible insulating material covering said conductors, said insulating material having large opposed surfaces, a heater disposed along and in contact with one of said surfaces to heat a limited region of some of said conductors, some of said conductors having the insulating material removed along the other of said opposed surfaces to expose said limited region of some of said conductors in a specific array, said heater including means for connection to a source of energy, said heater fixed in position relative to said flexible circuit to heat said limited regions, a circuit component having contacts disposed in a predetermined array corresponding at least in part to the specific array of said limited regions, and in contact with exposed limited regions of said conductors, and said arrays being bonded one to the other.

Claim 25

A connection arrangement comprising a flexible circuit having a plurality of flexible conductors disposed in and surrounded by flexible insulating material covering said conductors, said insulating material having large opposed surfaces, a heater disposed along and in contact with one of said surfaces to heat a limited region of some of said conductors, some of said conductors having the insulating material removed along the other of said opposed surfaces to expose said limited region of some of said conductors in a specific array, said heater including means for connection to a source of energy, said heater fixed in position relative to said flexible circuit to heat said limited regions, a circuit component having contacts disposed in a predetermined array corresponding at least in part to the specific array of said limited regions, and in contact with exposed limited regions of said conductors, and said arrays being bonded one to the other.

Claim 26

A connection arrangement according to claim 22 further comprising a block of insulating material having top and bottom surfaces and edge surfaces, at least one edge of said block having a further conductor extending thereon between said top and bottom surfaces, said circuit component having an electrical contact bonded to said further conductor, and one of said limited regions of one of said conductors being bonded to said further conductor at a location remote from said circuit member.

Claim 27

A circuit array according to claim 23 further comprising an electrically conductive contact one of said limited regions of said conductors of said flexible circuit having a further limited region of exposed conductor remote from the aforesaid limited region, a heater disposed on said flexible circuit on the surface thereof opposite said further exposed surface, said further exposed surface being bonded in electrical contact with said conductive contact.

Claim 28

The combination according to claim 23 wherein said further conductor is a heat bondable conductive material.

Claim 29

A connection arrangement according to claim 23 wherein said block has a castellation formed therein extending between said top and bottom surfaces, said further conductor disposed in said castellation.

Claim 30

A circuit array according to claim 26 wherein said block has a plurality of castellations in more than one of its edge surfaces; said castellations at least partially filled with said conductive material, said flexible circuit has a plurality of exposed regions of said conductors, and at least some of said exposed regions of said conductors of said flexible circuit contact and are bonded to said material lying between said top and bottom surfaces.

Claim 31

A circuit array according to claim 27 wherein said flexible circuit has a second array of exposed conductors remote from said first mentioned array, a selfregulating heater associated with said second array a circuit member having electrically conductive contacts, at least some of said second array of exposed conductors of said flexible circuit being in contact with at least some of said conductors of said circuit member.

Claim 32

A flexible circuit with heater comprising a generally rectangular flexible circuit having conductors, a flat narrow heater strip formed to define the four sides of a generally rectangular shape, and employed to heat conductors of said flexible circuit, said flexible circuit folded over said heater such that the corners of said flexible circuit all approach each other on one side of said heater.

Claim 33

A flexible circuit with heater comprising a generally rectangular flexible circuit having conductors, a flat narrow heater strip formed to define the four sides of a generally rectangular shape, and employed to heat conductors of said flexible circuit, said flexible circuit folded over said heater such that the corners of said flexible circuit all approach each other on one side of said heater.

Claim 34

A flexible circuit with heater according to claim 29 wherein at least some of the conductors of said flexible circuit are exposed on a side of said flexible circuit opposed to the surface contacting said heater.

Claim 35

A circuit array comprising a flexible circuit having a plurality of conductors disposed in and surrounded by insulating material covering said conductors, at least one said conductors having the insulating material removed therefrom to expose a region of said conductor, a block of insulating material having top and bottom surfaces and edge surfaces, at least one edge surface of said block having a further conductor extending thereon between said top and bottom surfaces, a circuit member having an electrical contact bonded to said further conductor, and said exposed region of said one of said conductors of said flexible circuit being bonded to said further conductor at a location remote from said circuit member.

Claim 36

A circuit array comprising a flexible circuit having a plurality of conductors disposed in and surrounded by insulating material covering said conductors, at least one said conductors having the insulating material removed therefrom to expose a region of said conductor, a block of insulating material having top and bottom surfaces and edge surfaces, at least one edge surface of said block having a further conductor extending thereon between said top and bottom surfaces, a circuit member having an electrical contact bonded to said further conductor, and said exposed region of said one of said conductors of said flexible circuit being bonded to said further conductor at a location remote from said circuit member.