FR4 Semiflex - cheaper than a cable harness? page 1 of 30

Transcription

1 FR4 Semiflex - cheaper than a cable harness? Webinar May 06, 2014 Speaker: Andreas Schilpp page 1 of 30

2 FR4 Semiflex - cheaper than a cable harness? Terms and definitions System comparision: cable harness versus FR4 Semiflex Design process Design rules, layer stack-up Production process Cost- / performance- relations processing FR4 Semiflex boards Application examples Outlook page 2 of 30

3 Terms and definitions 1 semi is a latin Prefix meaning half (Wikipedia) Flexibility : if you try to find this in Wikipedia you will find yourself in Stiffness (lat. flectere bending) (Wikipedia) not very precise and helpful So in this context everything is flexible??? Definition: FR4Semiflex = bendable Thin or partially thin with a special soldermask without flexible foils like PI page 3 of 30

4 Terms and definitions 2 Partial thickness reduction typically performed by depth routing Normally using a special routing bit (bevel, radius) (recommended!) Sometimes also using seperating foils or release lacquer pictures: Ruwel, WE page 4 of 30

5 Terms and definitions 3 Clarification regarding Duraflex (Isola 2005): never produced in serie Today Isola advertises Semiflex special FR4 thin laminates Influences on bendability are: thickness Resin and glas quality Mechanical design and routing Copper quality source: Isola, WE page 5 of 30

6 Big influence: Prepreg construction FR4 prepreg type 106 FR4 prepreg type 1080 FR4 prepreg type 2116 FR4 prepreg type 7628 dielectric thickness µm dielectric thickness µm dielectric thickness µm NOT suitable for microvias FR4 Semiflex Source: Isola page 6 of 30

7 System comparison: cable harness versus FR4 Semiflex Heterogeneous system Homogeneous system page 7 of 30

8 System comparison: cable harness versus FR4 Semiflex Heterogeneous system Homogeneous system Cheaper for very few contacts Lot of solder and contact points Detachable in case of connector Very robust (pulling on the cables) Less components, logistics easier Saving area for connector footprint or solder joints The best wiring safety Perfect testability Better signal integrity page 8 of 30

9 System comparison: angled connector vs. FR4 Semiflex page 9 of 30

10 Production process: FR4 Semiflex multilayer 8 layers page 10 of 30

11 Production process: FR4 Semiflex multilayer 8 layers page 11 of 30

12 Production process: FR4 Semiflex multilayer 8 layers page 12 of 30

13 Production process: FR4 Semiflex multilayer 8 layers page 13 of 30

14 Next up, we do a For an easy communication we use a logical structure for the naming of the stack-up comparable to flex-rigid What do you mean: Which one is the correct nomenclature of a FR4 Semiflex multilayer with - 8 layers, of which are - 1 copper layer in the bending area on TOP and - 1 copper layer in the bending area on Bottom? page 14 of 30

15 Design process Our vision of a system house: page 15 of 30

16 Design rules, layer stack-up WE Design rules always up-to-date on internet! unfavourable: copper free areas, small contour radii good: bending area filled with copper, large contour radii Layer stack-up: ask for proposal from WE! page 16 of 30

17 Design rules Regard bending direction S-shape bending with 2 bending areas! Optimize bearing construction page 17 of 30

18 Bending radii, bending angles, length of bending area Minimum bending radius R with bending area 1-layer: standard 5mm (as a comparison: flex-rigid 1mm) 1-layer with special adapted WE stack-up: 4mm 2-layers: after consultation (strongly dependant from stack-up) Count of bending cycles: typically 10 x with minimum bending radius Lengt L of bending area page 18 of 30

19 FR4 Semiflex: Pre-pending and fixation Well defined pre-bending prior to box installation! Assembly on plastic housing: page 19 of 30

20 Design: hints and tipps Linked chain reduced milling expenditure Single segments bended only some degrees! Replace big 180 areas by 2 x 90 with rigid intermediate section page 20 of 30

21 Cost- / performance- comparison: FR4 Semiflex vs. cable harness Cost Performance page 21 of 30

22 Cost- / performance- comparison: FR4 Semiflex vs. flex-rigid Cost Performance page 22 of 30

23 Next up, we do a. Where do you personally expect the biggest potential in changing from a cable harness to FR4 Semiflex? Multiple answers are possible! page 23 of 30

24 Application expample Measurement unit hydraulic drive Old solution! page 24 of 30

25 Application expample Measurement unit hydraulic drive - NEW Semiflex bare board assembled built in page 25 of 30

26 Application expample TPC84 Touchscreen control panel with Ethernet / TCP/IP connection page 26 of 30

27 Application expample Switchbox 12 x 13 Applications: Groundwater exploration, geotechnical investigation, monitoring of dams and dikes, environmental studies, geological survey, mineral prospecting, archaeology, detecting of cavities and buried objects, underwater, marine, borehole and cross-hole measurements page 27 of 30

28 Application expample Switchbox 12 x page 28 of 30

29 Application expample Switchbox 12 x page 29 of 30

30 Outlook In development: bending area with 3 layers Power Semiflex: combination with welded WIRELAID wires page 30 of 30