Can flex PCBs be used
Unlike rigid PCBs, which are essentially woven fiberglass impregnated in epoxy resin, flexible printed circuit boards (flex PCBs) consist of a conductor layer (typically copper traces) laminated to a flexible dielectric material such as polyimide or thin flexible glass fiber and epoxy. A thin film or layer of insulating material called a coverlay is then applied to both sides of the conductor layers to provide insulation, and protection from damage and corrosion to the conductors. The coverlay is also a substrate for soldering and conductive adhesive bonding of components to the flex circuit.
A flex pcb can be made from a variety of materials, including copper foil, which is the most common. However, it’s important to note that not all types of copper are suitable for use in a flex circuit. For example, thicker copper foil increases the stress in a flex circuit and can cause it to crack or break. For this reason, it’s best to only use the highest quality copper available for your flex PCB.
In order to maintain flexibility in a flex circuit, it’s important to limit the number of layers on the board and to route the traces perpendicular to the bend line. This minimizes stress points and prevents the traces from breaking during manufacturing or bending. For higher layer count flex circuits, it’s also recommended to use an air-gap technique such as solder mask on copper to separate the conductor layers.
Can flex PCBs be used in flexible electronic tattoos?
The key to ensuring the reliability of a flex or rigid-flex circuit is ensuring that it’s designed for manufacturability. This requires careful modeling of the product’s operating environment, which can include extreme temperatures and exposure to chemicals, shock and vibration. In addition, the physical design of the flex or rigid-flex circuit needs to be modeled to ensure that it can withstand the required minimum bending radius.
One of the most common reasons for a flex or rigid-flex circuit to fail in the field is due to broken copper traces and cracked vias. This can occur due to the stress of a tight bending radius, the lack of a proper reference plane or shielding, or simply because of the materials used in the fabrication process. In order to avoid this, it’s important to work closely with a fabricator to select the right material for the job.
Using flex circuits in the electronics industry allows manufacturers to produce more innovative and intuitive products. For example, robotic limbs and grippers utilize flex circuits to allow them to adapt to the human body. Meanwhile, e-paper displays and smartphones leverage the inherent flexibility of flex circuits to create curved or foldable designs. Regardless of what you’re designing for, the tools in Altium Designer enable your team to create a flex or rigid-flex circuit that can meet your specific requirements. The fully integrated PCB editor, Draftsman automation, and real-time supply chain data are a great way to streamline the entire process of bringing your product to market.
