Method for the connection and repair of flex and other circuits

A method for the repair of electrical circuits, comprising the steps of:

• (a) providing an electrical assembly which includes:
• (i) first and second electrical circuits having respective first and second edges thereof, wherein each electrical circuit has a plurality of circuit traces thereon or therewithin terminating proximate the respective first or second edge;
• (ii) an interconnecting member comprising a flexible dielectric substrate having third and fourth edges and a plurality of circuit traces arranged on or within the substrate, wherein each trace extends from proximate the third edge to proximate the fourth edge, wherein each circuit trace includes first and second connection features thereof disposed proximate the third and fourth edges, respectively, and at least one third connection features thereof disposed between the third and fourth edges, wherein each of the connection features is a plated through hole, a plated blind via, or a mounting pad;
• (iii) wherein the first and second electrical circuits are arranged with the first and second edges thereof overlapping the third and fourth edges of the interconnecting member, respectively, with the circuit traces of the first and second electrical circuits being mechanically and electrically connected to corresponding circuit traces of the interconnecting member at the first and second connection features, respectively;
• (b) cutting the interconnecting member thereacross between the first connection features and the third connection features, thereby severing the first electrical circuit from the interconnecting member and thereby presenting a fifth edge of the interconnecting member proximate the third connection features;
• (c) providing a third electrical circuit similar to the first electrical circuit and a second interconnecting member comprising a flexible dielectric substrate having seventh and eighth edges and a plurality of circuit traces arranged on or within the substrate, wherein each trace extends from proximate the seventh edge to proximate the eighth edge, wherein each circuit trace includes fourth and fifth connection features thereof disposed proximate the seventh and eighth edges, respectively, and at least one sixth connection features thereof disposed between the seventh and eighth edges, wherein each of the connection features is a plated through hole, a plated blind via, or a mounting pad;
• (d) arranging the second interconnecting member and the third electrical circuit such that a sixth edge of the third electrical circuit contactedly overlaps the seventh edge of the second interconnecting member and the eighth edge contactedly overlaps the fifth edge of the interconnecting member;
• and
• (e) mechanically and electrically connecting circuit traces of the third electrical circuit with corresponding circuit traces on the second interconnecting member at the fourth connection features, and the circuit traces of the second interconnecting member with corresponding circuit traces on the interconnecting member at the third and fifth connection features.