A flexible circuit with multiple independent mounting points can be mounted (soldered) to substrates by independently (and concurrently) positioning mounting points in x, y, and theta (angular rotation) with vacuum chucks. In one embodiment the vacuum chucks can be guided by computer aided vision to
A flexible circuit with multiple independent mounting points can be mounted (soldered) to substrates by independently (and concurrently) positioning mounting points in x, y, and theta (angular rotation) with vacuum chucks. In one embodiment the vacuum chucks can be guided by computer aided vision to locate and match fiducials on the flex circuit with fiducials on the substrate. In one embodiment, hot bars can be used in a subsequent bonding operation to secure an adhesive coupling between the flexible circuits and the substrate.
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1. A method for aligning and bonding a flexible circuit having a plurality of attaching surfaces to a plurality of mounting areas, the method comprising: securing the flexible circuit to a securing mechanism, the securing mechanism having at least as many securing areas as there are attaching surfac
1. A method for aligning and bonding a flexible circuit having a plurality of attaching surfaces to a plurality of mounting areas, the method comprising: securing the flexible circuit to a securing mechanism, the securing mechanism having at least as many securing areas as there are attaching surfaces;concurrently lifting a first attaching surface and a second attaching surface using the securing mechanism;using an optical guidance system to direct the securing mechanism in aligning the first attaching surface with a first mounting area and independently aligning the second attaching surface with a second mounting area; andbonding the first attaching surface to the first mounting area and the second attaching surface to the second mounting area. 2. The method as recited in claim 1, wherein the securing mechanism comprises: a first vacuum chuck; anda second vacuum chuck,wherein the securing the flexible circuit comprises attaching the first vacuum chuck to the first attaching surface and attaching the second vacuum chuck to the second attaching surface. 3. The method as recited in claim 2, wherein the optical guidance system comprises: a plurality of fiducials disposed on the plurality of attaching surfaces, each of the plurality of attaching surfaces having at least one fiducial corresponding to a fiducial disposed proximate to one of the plurality of mounting areas; anda plurality of CCD cameras, providing optical guidance by supplying at least an input to the first and second vacuum chucks when one of the plurality of fiducials is in alignment. 4. The method as recited in claim 3, wherein at least one of the plurality of CCD cameras is able to view one of the plurality of fiducials by way of a mirror. 5. The method as recited in claim 3, wherein at least one of the plurality of CCD cameras is able to view two complementary pairs of fiducials by way of a series of mirrors splitting a field of view of the at least one CCD camera into two portions. 6. The method as recited in claim 3, wherein each of the plurality of mounting areas comprises: a bonding pad electrically coupled to a touch sensor; anda conductive, pressure sensitive adhesive strip overlaying the bonding pad. 7. The method as recited in claim 6, further comprising: prior to the bonding step applying force between the first attaching surface and the bonding pad corresponding to the first mounting area, the resulting pressure yielding a pre-bond that at least temporarily joins the first attaching surface to the first mounting area. 8. The method as recited in claim 1, further comprising: pre-positioning the flexible circuit on a stage prior to the flexible circuit being secured by the securing mechanism, the stage configured to pre-position the flexible circuit in a geometry substantially the same as a final geometry taken by the flexible circuit once it is bonded to the plurality of mounting areas. 9. The method as recited in claim 8, wherein a portion of the stage has a shape substantially similar to an obstruction around which the flexible circuit is routed. 10. The method as recited in claim 4, wherein the bonding of the first and second attaching surfaces comprises using a first and second hot bar to bond the first and second attaching surfaces to the first and second mounting areas. 11. A system for electrically coupling a flexible circuit to a plurality of electrical contacts arranged on a display assembly, comprising: an optical guidance system comprising a plurality of CCD cameras arranged to observe fiducials disposed on a first surface of the display assembly and corresponding fiducials disposed on the flexible circuit;a plurality of vacuum chucks configured to independently maneuver a plurality of attaching surfaces of the flexible circuit until a plurality of fiducial marks on the flexible circuit are in alignment with corresponding fiducial marks on the first surface of the display assembly; anda plurality of hot bars configured to adhesively and electrically couple the plurality of attaching surfaces to associated electrical contacts arranged on the display assembly by a conductive, pressure sensitive adhesive. 12. The system as recited in claim 11, wherein a relative position between corresponding fiducials tracked by the optical guidance system is used as an input for an automated feedback control system guiding the plurality of vacuum chucks, thereby quickly aligning the attaching surfaces of the flexible circuit. 13. The system as recited in claim 12, wherein when the plurality of vacuum chucks align the plurality of fiducial marks the plurality of vacuum chucks are configured to concurrently lower the plurality of attaching surfaces onto the first surface of the display assembly, the lowering resulting in an application of pressure between the plurality of attaching surfaces and the first surface of the display assembly, thereby resulting in a pre-bond between the plurality of attaching surfaces and the first surface of the display assembly. 14. The system as recited in claim 13, wherein the optical guidance system further comprises: a series of optics configured to allow a standoff distance between the CCD cameras and the first surface of the display assembly. 15. The system as recited in claim 11, wherein a portion of the first attaching surface has a portion of the coverlay removed to facilitate faster heat transfer between one of the plurality of hot bars and the conductive pressure sensitive adhesive. 16. A non-transitory computer readable medium for storing computer instructions executed by a processor in a computing device, the computer readable medium comprising: computer code for pre-bending a flexible circuit, the flexible circuit comprising a first and second attachment surface;computer code for concurrently aligning the first and second attachment surfaces to alignment indicia arranged on a first surface of an electrical component by independently maneuvering the first and second attachment surfaces with a first vacuum chuck attached to the first attachment surface and a second vacuum chuck attached to the second attachment surfaces;computer code for pressing the first and second attachment surfaces onto the first surface of the electrical component, wherein the pressing of the first and second attachment surfaces onto the first surface of the electrical component pre-bonds the first and second attachment surfaces onto the first surface of the electrical component together; andcomputer code for adhesively and electrically coupling the first and second attachment surfaces to the first surface of the electrical component by a plurality of hot bars. 17. The non-transitory computer readable medium as recited in claim 16, wherein the pre-bending is performed on a stage that simulates the environment in which the flexible circuit will be bonded. 18. The non-transitory computer readable medium as recited in claim 17, further comprising: computer code for lifting the flexible circuit off the stage by a first and second vacuum chuck at the first and second attachment surfaces respectively; andcomputer code for maintaining a relative position between the first and second attachment surfaces when transporting the flexible circuit from a position over the stage to a position over the first surface of the electrical component. 19. The non-transitory computer readable medium as recited in claim 16, wherein the alignment indicia are fiducials arranged on both the first and second attachment surfaces and on the first surface of the electrical component. 20. The non-transitory computer readable medium as recited in claim 16, wherein the electrical component comprises: a plurality of electrical contacts disposed across the first surface of the electrical component, anda plurality of conductive, pressure sensitive adhesive strips disposed over the plurality of electrical contacts.
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