Article12 Dec 2021 22:39
https://www.newelectronics.co.uk/electronics-technology/early-detection/242677/
Enter Trackwise, a UK company that specialises in long, single- and multi-layer flexible printed circuits (FPC). FPC manufacturing techniques have traditionally limited their length to less than one metre, but a patented innovation in the manufacturing process by Trackwise called Improved Harness Technology (IHT) has removed these restrictions, opening up many new applications.
Unlike conventional FPC manufacturing techniques that are based on static process steps, IHT uses dynamic processes based on reel-to-reel techniques to enable the cost-effective production of length-unlimited multi-layer FPCs. Recently, Trackwise broke its own record by producing a 72m long FPC for an energy generation company that contains 434,652 through holes and 434, 636, all plated, with a total routed path length of 4785m.
FPCs, of course, deliver many advantages over traditional harness interconnect systems. FPCs take up considerably less space and weigh much less than wiring harnesses. Very thin dielectric substrates, some down to 40µm or less, coupled with their planarity, also make it possible to bond the circuits to, or within, the structure of a product, enabling multi-functional structures. Total system weight savings also result because fewer connectors and fixings are required. Smaller conductors and reduced copper content make an additional contribution.
FPCs are very versatile, as they are custom-designed to fold, bend and fit into virtually any shape of housing. They are also more reliable since they have fewer interface connections. Physically, FPCs are more resistant to vibration and shock than rigid PCBs.
In terms of electrical performance, crosstalk, noise and electromagnetic compatibility (EMC) are all tightly controlled by the FPC manufacturing process. FPC layer build constructions can provide lower inductance and lower radiated emissions than conventional wiring, and impedance control is more easily achieved. Flat foil conductors within the FPC can dissipate heat better and carry more current than equivalent round wires.
Significantly, FPCs lead to cost reduction thanks to a number of factors: simplified assembly; elimination of wiring errors; reduced component count; higher levels of automation resulting in greater repeatability and precision; and lower installation costs.
WrapSense
Direct-C approached Trackwise, because of the company's proven ability to produce long FPCs, and together with test house TWI, the three companies have successfully built and trialled one-piece, 26m-long strips of WrapSense.
According to Direct-C's Chief Science Officer, Stephen Edmondson, "Our main concern was ruggedness and reliability. A 10m long WrapSense produced using separate smaller 50cm lengths might contain 300 solder joints - and each one is a potential failure point. With a continuous strip, you have, perhaps, only eight solder joints, so the unit
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