At first glance, the surface appearance of PCB designs may seem similar, irrespective of their internal quality. However, it is through these surface features that we can discern significant differences, which are crucial to the lifespan and functionality of the printed circuit board.
Whether during manufacturing and assembly or in actual operation, the design of the PCB must demonstrate reliable performance, which is paramount. Beyond associated costs, any defects that arise during the assembly process can be introduced into the final product due to the PCB design, potentially leading to failures during use and subsequent claims. From this perspective, it is fair to assert that the expense associated with high-quality PCB design is minimal.
In all market segments, particularly those producing goods in critical application areas, the repercussions of such failures can be catastrophic.
These factors should be considered when evaluating PCB prices. While the initial investment in reliable, guaranteed, and long-lasting products may be higher, it is ultimately worthwhile over time.
**PCB Board Design**
**Key Features of High-Reliability Circuit Boards:**
1. **25 Micron Hole Wall Copper Thickness**
**Advantages:** Enhanced reliability, including better resistance to Z-axis expansion.
In practical applications, under load conditions, issues such as blow holes or degassing can lead to assembly failures (e.g., inner layer separation or hole wall rupture), resulting in electrical connection problems. The IPC standard (adopted by most manufacturers) specifies a requirement for 20% less copper plating.
2. **No Welding Repair or Open Circuit Repair Lines**
**Advantages:** A complete circuit ensures reliability and safety, with no maintenance required and no associated risks.
If repairs are not executed properly, the circuit board may become compromised. Even if a repair is deemed “correct,” there remains a risk of failure under load conditions (such as vibration), which can lead to actual use failures.
3. Exceeding the cleanliness requirements of the instrument panel combination instrument specification
Benefits: Enhancing PCB cleanliness can significantly boost reliability.
Residue and solder buildup on the circuit board pose risks to the solder mask. Ionic residues can lead to corrosion and contamination on the soldering surface, potentially resulting in reliability issues, such as poor solder joints and electrical failures, ultimately increasing the risk of actual failure.
4. Strictly control the service life of each surface treatment.
Advantages: Improved solderability, reliability, and reduced moisture intrusion risk.
Metallographic changes in the surface treatment of aging circuit boards may lead to soldering issues, while moisture intrusion can cause delamination, separation of inner layers, and open circuits, alongside other complications during assembly or actual use.
5. Use internationally recognized substrates—avoid “local” or unknown brands.
Advantages: Enhanced reliability and established performance.
Subpar mechanical performance can prevent the circuit board from meeting its expected performance during assembly. For instance, high expansion characteristics may lead to delamination, open circuits, and warpage. Diminished electrical properties can result in inadequate impedance performance.
6. The tolerance of the copper-clad laminate complies with the 4101 standard of the International Electrotechnical Commission.
Advantages: Precise control of dielectric layer thickness reduces deviations from expected electrical performance.
Electrical performance might fail to meet specified standards, leading to significant variations in output/performance within the same batch of components.
7. Define solder mask materials to ensure compliance with IPC-SM-840 standard requirements.
Advantages: The NCAB Group endorses “excellent” inks to guarantee ink safety and compliance with UL standards for solder mask inks.
Inferior inks may lead to issues with adhesion, flux resistance, and hardness, ultimately causing the solder mask to detach from the circuit board and resulting in copper circuit corrosion. Insufficient insulation can trigger short circuits due to unintended electrical connections or arcs.
8. Define the tolerances of mechanical features such as shapes and holes.
Advantages: Rigorous tolerance control enhances the dimensional quality of products, improving fit, appearance, and functionality.
Assembly process challenges, such as alignment and fitting issues (e.g., with press-fit pins), may only be identified after assembly. Additionally, increased dimensional deviations can lead to complications during base installation.
9. NCAB specifies the thickness of the solder mask, despite the absence of relevant regulations in the International Chemical Safety Program.
Advantages: Enhanced electrical insulation reduces the risk of peeling or loss of adhesion and strengthens resistance to mechanical shocks, regardless of where they occur!
A thin solder mask can lead to adhesion, solder resistance, and hardness issues, resulting in the solder mask detaching from the circuit board and copper circuit corrosion. Insufficient insulation from a thin solder mask may cause short circuits due to accidental conduction or arcs.
10. The appearance and repair requirements are defined, even though the instrument cluster is not specifically outlined.
Benefits: Exercise caution during the PCB manufacturing process to ensure casting safety.
Various scratches, minor damages, repairs, and fixes may render the circuit board usable, but not aesthetically pleasing. Beyond visible issues, what other hidden risks affect assembly and pose dangers during actual use?
11. Plug hole depth requirements.
Advantages: High-quality plug holes minimize the risk of assembly failures.
Chemical residues from the gold deposition process may linger in inadequately plugged holes, leading to weldability issues and other complications. Furthermore, tin beads may remain concealed in holes, potentially causing short circuits during assembly or actual use.
12. Peters 2955 specifies the brand and model of peelable blue glue.
Benefit: Specifying peelable blue glue helps avoid inferior “local” or cheap brands.
Low-quality or inexpensive peelable adhesives may foam, melt, crack, or harden during the assembly process, similar to concrete, making them difficult to remove or ineffective.
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Feel free to let me know if you need any further modifications!
Whether during manufacturing and assembly or in actual operation, the design of the PCB must demonstrate reliable performance, which is paramount. Beyond associated costs, any defects that arise during the assembly process can be introduced into the final product due to the PCB design, potentially leading to failures during use and subsequent claims. From this perspective, it is fair to assert that the expense associated with high-quality PCB design is minimal.
In all market segments, particularly those producing goods in critical application areas, the repercussions of such failures can be catastrophic.
These factors should be considered when evaluating PCB prices. While the initial investment in reliable, guaranteed, and long-lasting products may be higher, it is ultimately worthwhile over time.
**PCB Board Design**
**Key Features of High-Reliability Circuit Boards:**
1. **25 Micron Hole Wall Copper Thickness**
**Advantages:** Enhanced reliability, including better resistance to Z-axis expansion.
In practical applications, under load conditions, issues such as blow holes or degassing can lead to assembly failures (e.g., inner layer separation or hole wall rupture), resulting in electrical connection problems. The IPC standard (adopted by most manufacturers) specifies a requirement for 20% less copper plating.
2. **No Welding Repair or Open Circuit Repair Lines**
**Advantages:** A complete circuit ensures reliability and safety, with no maintenance required and no associated risks.
If repairs are not executed properly, the circuit board may become compromised. Even if a repair is deemed “correct,” there remains a risk of failure under load conditions (such as vibration), which can lead to actual use failures.
3. Exceeding the cleanliness requirements of the instrument panel combination instrument specification
Benefits: Enhancing PCB cleanliness can significantly boost reliability.
Residue and solder buildup on the circuit board pose risks to the solder mask. Ionic residues can lead to corrosion and contamination on the soldering surface, potentially resulting in reliability issues, such as poor solder joints and electrical failures, ultimately increasing the risk of actual failure.
4. Strictly control the service life of each surface treatment.
Advantages: Improved solderability, reliability, and reduced moisture intrusion risk.
Metallographic changes in the surface treatment of aging circuit boards may lead to soldering issues, while moisture intrusion can cause delamination, separation of inner layers, and open circuits, alongside other complications during assembly or actual use.
5. Use internationally recognized substrates—avoid “local” or unknown brands.
Advantages: Enhanced reliability and established performance.
Subpar mechanical performance can prevent the circuit board from meeting its expected performance during assembly. For instance, high expansion characteristics may lead to delamination, open circuits, and warpage. Diminished electrical properties can result in inadequate impedance performance.
6. The tolerance of the copper-clad laminate complies with the 4101 standard of the International Electrotechnical Commission.
Advantages: Precise control of dielectric layer thickness reduces deviations from expected electrical performance.
Electrical performance might fail to meet specified standards, leading to significant variations in output/performance within the same batch of components.
7. Define solder mask materials to ensure compliance with IPC-SM-840 standard requirements.
Advantages: The NCAB Group endorses “excellent” inks to guarantee ink safety and compliance with UL standards for solder mask inks.
Inferior inks may lead to issues with adhesion, flux resistance, and hardness, ultimately causing the solder mask to detach from the circuit board and resulting in copper circuit corrosion. Insufficient insulation can trigger short circuits due to unintended electrical connections or arcs.
8. Define the tolerances of mechanical features such as shapes and holes.
Advantages: Rigorous tolerance control enhances the dimensional quality of products, improving fit, appearance, and functionality.
Assembly process challenges, such as alignment and fitting issues (e.g., with press-fit pins), may only be identified after assembly. Additionally, increased dimensional deviations can lead to complications during base installation.
9. NCAB specifies the thickness of the solder mask, despite the absence of relevant regulations in the International Chemical Safety Program.
Advantages: Enhanced electrical insulation reduces the risk of peeling or loss of adhesion and strengthens resistance to mechanical shocks, regardless of where they occur!
A thin solder mask can lead to adhesion, solder resistance, and hardness issues, resulting in the solder mask detaching from the circuit board and copper circuit corrosion. Insufficient insulation from a thin solder mask may cause short circuits due to accidental conduction or arcs.
10. The appearance and repair requirements are defined, even though the instrument cluster is not specifically outlined.
Benefits: Exercise caution during the PCB manufacturing process to ensure casting safety.
Various scratches, minor damages, repairs, and fixes may render the circuit board usable, but not aesthetically pleasing. Beyond visible issues, what other hidden risks affect assembly and pose dangers during actual use?
11. Plug hole depth requirements.
Advantages: High-quality plug holes minimize the risk of assembly failures.
Chemical residues from the gold deposition process may linger in inadequately plugged holes, leading to weldability issues and other complications. Furthermore, tin beads may remain concealed in holes, potentially causing short circuits during assembly or actual use.
12. Peters 2955 specifies the brand and model of peelable blue glue.
Benefit: Specifying peelable blue glue helps avoid inferior “local” or cheap brands.
Low-quality or inexpensive peelable adhesives may foam, melt, crack, or harden during the assembly process, similar to concrete, making them difficult to remove or ineffective.
—
Feel free to let me know if you need any further modifications!
