Designing Flexible Circuits
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Company name and address are optional.
The course was written by
John Michael Pierobon
, who has an advanced engineering degree from Purdue University. John Michael has taught hundreds of technical courses throughout the world, and speaks several languages fluently.
Go to the outline of:
Course Introduction
Flexible Circuits
Design Options
Flexible Circuit Materials
Flexible Circuit Requirements
Design Guidelines For Flexible Circuits
Light Emitting Diodes In Flexible Circuits
Flexible Heaters
Conclusion
Glossary
Chapter 0
Course Introduction
Course Objectives
Intended Audience
Course Structure
Course Content
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Chapter 1
Flexible Circuits
What Are Flexible Circuits
Origin Of Flexible Circuits
Advantages Of Flexible Substrates
Applications
Industrial Applications
Automotive
Computer Peripherals
Consumer
Instruments
Medical
Military
Telecom
Types Of Flexible Circuits
Flex
Rigid-Flex
Flexible Coil
Main Benefits Of Flexible Circuits
Thermoelectric
High Reliability
Repeatable installation.
Harsh environments.
Long duty cycles.
High vibration.
Superior Packaging
Flex Versus Wiring Harness
Flex Versus Printed Circuit Board
Advantages Of Rigid-Flex
Double side component mounting.
Improved impedance control.
Vibration resistance.
High mass component mounting.
Chapter 1 Review Questions
Chapter 1 Review
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Chapter 2
Design Options
Association Connecting Electronics Industries
Single-Sided Flexible Circuits
When To Use Single-Sided Flexible Circuits
Double-Sided Flexible Circuits
When To Use Double-Sided Flexible Circuits
Multi-Layer Flexible Circuits
When To Use Multi-Layer Flexible Circuits
Rigid-Flex Flexible Circuits
Rigid-Flex Features
Multi-Layer Not Plated Flexible Circuits
Design Options
More Design Options
Terminators
Connectors
High Density Connectors
Fingers
Pins
Types Of Pins
Flexible Coil Circuits
There are three basic types of flexible coil circuits.
Simple, flat coils with wire leads.
Coils laminated inside flexible circuits.
Rim coils that are built up along the Z-axis.
Design Considerations For Rigid Flex
More Design Considerations For Rigid Flex
Benefits Of Using A Stiffener
More On Using A Stiffener
Stiffener Material
Stiffener Hole
Through Hole
Wiring Hole
Vias
Pads
Pad Fillets
Surface Mount Access
Chapter 2 Review Questions
Chapter 2 Review
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Chapter 3
Flexible Circuit Materials
Components Of Flexible Circuits
Base Material
Adhesive
Metal Foil
Characteristics Of Flexible Circuit Laminates
Dimensional Stability
Thermal Resistance
Tear Resistance
Chemical Resistance
Low Moisture Absorption
Low Cost
Types Of Base Material
Comparing Polyester And Polyimide
Base Material Properties
Types Of Adhesive
Acrylic Adhesive
Butyral-Phenolic Adhesive
Epoxy Adhesive
Polyester Adhesive
Polyimide Adhesive
Adhesive Properties
Types Of Copper Foil
Copper Foil For Printed Wiring Applications
Electrodeposited Copper
Wrought Copper
Electroplated Copper
Circuit Lay Out To Conserve Material
Nesting
Chapter 3 Review Questions
Chapter 3 Review
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Chapter 4
Flexible Circuit Requirements
Steps To Defining Flexible Circuit Requirements
End Product Requirements
Reliability Requirements
Operating Environment Requirements
Operating Temperature Ranges
Package Configuration
Mechanical Requirements
Electrical Requirements
Location Of Components
Assembly Method
Electrical Testing
Mechanical Testing
Create A Demonstration Circuit
Build A Flexible Circuit Mock Up
Steps To Build A Flexible Circuit Mock Up
Create CAD Data
Additional Steps
Chapter 4 Review Questions
Chapter 4 Review
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Chapter 5
Design Guidelines For Flexible Circuits
Flexible Circuit Versus Hardboard
Tolerance Settings In Flexible Circuit Design
Use Of Multiple Datum
Guidelines For Dimensioning
Tolerances
Standard Design Recommendations For Tolerances
Conductor Width, Thickness, And Spacing
Designing With Copper
Weight Is A Cost Factor
Cost Impact Of Layer Count
More On Cost Impact Of Layer Count
Manufacturing Cost Of A Flex Circuit
Manufacturing Steps
Ways To Minimize Circuit Cost
Controlling Impedance And Electrical Noise
Ways To Control Impedance And Electrical Noise
Service Loops
Staggered Length Circuits
Forming
Forming Factors
Bend Radii
Bend Ratio
More On Bend Radii
Copper Plating
Stressors
Time And Temperature
Conductor Routing
Sharply Angled Conductors
How To Improve Flexibility And Bend Radius
Minimum Bend Radius
Reduce Thickness In The Flex Area
Make The Circuit Robust To Withstand Flexing
More On How To Withstand Flexing
Even More On How To Withstand Flexing
Ground Plate Design
Pads, Holes, And Annular Rings
General Requirements For Pads, Access Holes And Annular Rings
Design Requirements For Pads, Access Holes And Annular Rings
Sizing Vias
Fillets
Hold-Down Tabs
Plated Through Holes
Covercoating
Sizing Coverlayer Openings
Tear Resistance
Ways To Prevent Tearing
Trimming
Chapter 5 Review Questions
Chapter 5 Review
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Chapter 6
Light Emitting Diodes In Flexible Circuits
Light Emitting Diodes
A Light Emitting Diode (LED) is based on the semiconductor diode.
Light Emitting Diodes have been primarily concentrated in consumer electronics markets.
Benefits Of Light Emitting Diodes
Types Of Light Emitting Diodes
Light Emitting Diodes Today
The Effect Of Temperature
Thermal Management
Material And Light
Chapter 6 Review Questions
Chapter 6 Review
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Chapter 7
Flexible Heaters
What Are Flexible Heaters
Flexible heaters are thin, bendable devices that can be shaped to fit any object to be heated.
Flexible Heater Applications
Shapes And Sizes
Types Of Flexible Heaters
Polyimide Heaters
Silicone Rubber Heaters
Transparent Heaters
Mica Heaters
Polytetrafluoroethylene Heaters
Temperature Range Of Flexible Heaters
The Principle Of Joule Heating
Flexible heaters work on the principle of Joule heating.
Ohm's Law
Design Requirements
Calculate Power Requirements
Calculate Power Requirements Example
Add A Safety Factor
Watt Density
Watt Density Charts
High Watt Density
More On High Watt Density
Use More Heaters
Mounting Method
Steps To Selecting A Flexible Heater
Chapter 7 Review Questions
Chapter 7 Review
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Chapter 8
Conclusion