Flex Circuit Boards Contribute to Reduced Assembly Time
A flex circuit board is one that has the ability to be bent or curved in ways that are normally not possible with rigid PCBs. The flexible nature of the PCB allows it to be shaped to fit in various types of applications, which can save time and space on assembly. This can be a huge benefit in areas where space is limited and a high degree of flexibility is required.
The PCB’s flexible structure also makes it easier to install, which cuts down on labor costs as well. These features are especially useful in the automotive industry where a number of electronics are integrated into modern cars. This technology can include everything from the vehicle’s GPS software to the dashboard and rear-view camera. By replacing traditional wiring harnesses and ribbon connectors, flex circuit board can significantly reduce installation time in cars.
Despite their flexible construction, flex circuit boards are not without their challenges. Several considerations should be made in the design phase to ensure that the PCB will be able to perform correctly when it is flexed or bent for assembly. For example, the conductive layers should be kept as close together as possible in order to minimize the amount of stress that is placed on the copper trace when the circuit is flexed or bent. It is also a good idea to stagger the traces so that there are no areas of direct contact with each other when they are being flexed or bent.
How Do Flex Circuit Boards Contribute to Reduced Assembly Time?
In addition, the thickness of the conductive layer should be kept as low as possible in order to maintain flexibility while maintaining adequate conductivity. Copper foil is the most common conductive material for flex circuits, but other metals are available when special properties are required such as springiness or radiodensity. It is also important to choose a suitable base material for the flex circuit, as this will affect cost and flexibility.
In most cases, manufacturers will use a Polyimide (PI) film as the base for a single-layer flex PCB. While this is thinner than the FR-4 used in rigid PCBs, it still provides strength and reliability. In some cases, a stiffener may be added to certain regions of the flex PCB in order to increase the stability and durability of the resulting product.
It is also important to consider the types of coverlay, solder mask, and stiffeners that will be used on a flex circuit. These will all differ from those used on rigid PCBs, and they can add to the cost of a flex circuit. Generally, it is best to route traces through flex zones perpendicularly, as this will maximize their etch yield and material strength while minimizing the risk of damage during assembly.
Finally, the flex circuit should be thoroughly tested to ensure that it will bend properly and remain stable during its lifespan. This testing will typically involve constructing a virtual mock-up of the circuit in its formed installed configuration using a 3D CAD program. In addition, a mechanical sample will be provided to evaluate any form or fit concerns that might exist.