Limitations of Flexible Circuit Boards
As electronics have gotten smaller, flexible circuit boards are now capable of integrating many functions into one compact unit. This technology is ideal for saving space and improving the flexibility of a product’s design, making it easier to assemble and transport. However, there are several limitations to using a flexible circuit board that are important for designers to be aware of.
One of the main limitations of a flexible circuit board is its higher manufacturing cost. This is due to the use of special materials and processes in the manufacture of a flex PCB, including polyimide (PI) substrate material, thin-film plating and lamination. In addition, a flex PCB must be designed to meet specific requirements for manufacturability, which requires extensive collaboration between designers and manufacturers.
Another limitation of a flexible circuit board is its susceptibility to damage, which can be caused by a number of factors. These include improper circuit layout design, incorrect material selection and mistakes during the manufacturing process. Additionally, a flexible circuit board needs to be able to withstand repeated bending, which can cause the copper layers to wear out.
The Limitations of Flexible Circuit Boards
A flex circuit board’s conductors are typically covered with Polyimide (PI), which provides a stronger and more durable layer of protection than solder masks. This is particularly helpful for preventing abrasion and damage to the conductors from harsh environmental conditions, such as high temperatures, humidity and corrosive chemical substances.
While a flexible circuit board can be used in various environments, it is generally not recommended for use in extreme or harsh conditions. These conditions can negatively affect the performance of the board, causing it to malfunction or even break down altogether.
Another limit of a flex circuit is its limited size. Because a flex PCB is made from a single base map or programmed light drawing program, it can only be produced in small sizes that are limited by the size of the original base map or programming. This limits the maximum length and width of the circuit board.
Lastly, it is essential for designers to be familiar with the different flex classifications before designing their PCB. There are different standards and requirements for each class, and a flex circuit board that fails to meet these requirements will not be able to function properly.
Considering the benefits of flexible circuit boards, it’s clear to see why they have become a standard for modern electronics. These versatile and adaptable circuits can be used to create products with a more streamlined assembly process, improved flexibility and increased reliability. For more information about how a flex circuit can benefit your company, contact us at Epec. Our knowledgeable experts are happy to discuss your requirements and provide advice on the best solution for your needs. We look forward to hearing from you!