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Factors Governing Reliability in Flex Circuit Designs
Effective flex circuit designs are intended to make flexible circuits that function in severe settings, withstand vigorous flexing cycles, decrease influence of excessive vibrations and fit in whichever shape required. A flex circuit design is initiated by defining needs of finished assembly. Careful attention is given in designing conductor layout. Choosing right base material that ensure reliability, improve design value and retain flexural characters with a component stack-up is also one essential feature of effective flex circuit design.
Factors ensuring reliability of flex circuit designs
Bend radius is a crucial factor that determines reliability of flex circuits. Full thickness of circuit and its point of flexion are also significant. A ratio of bend radius to thickness determines reliability and success of a flex circuit. For circuits to perform well, bend radius needs to be ten times its material thickness.
There must not be copper plating within flexing area on top of conductors. External “pads-only” layers on top of flex circuits (excluding copper, nickel or gold plating) allow reduced plating thickness. This helps in lessening the entire circuit thickness.
Decreasing thickness of dielectrics or lessening weight of base copper is another method to enhance reliability of the flex circuitry. By using base materials needing no adhesives, designers can create flex circuit designs that are thin and highly flexible. Although reducing some mils appears insignificant, it helps in getting bend ratio to 10:1.
The kind of dielectrics used is another important factor. Different dielectrics have dissimilar flexural properties, even if they have same thickness. It is always better to use material that is more flexible since this helps in enhancing flexibility of flex circuits.
Options to Improve Value of Flex Circuit Design
Terminations can be added by using connectors, pins and fingers. Stiffeners are often used as cheap sources to render firmness to pins, surface mount and hole-areas. When designing the forming, at bend zone, remain from the use of mechanical stressors. Appropriate design is chosen for forming process. It helps formed parts to decrease their susceptibility to temperature. Specialists in flex circuitry designing develop reasonably priced, customized flex circuitry designs that meet precise usability specifications.
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