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Copper Foil mechanical fatigue in
flexible printed circuits
subject to high cycle vibration
04/22/2009
Don Blanchet
3B Associates
339-234-3544
Scope
 Present information on the
metallurgical structure of 2 copper foil
structures used in flex circuit design
for a vibration environment
– RA, rolled annealed
– ED, electrodeposited
 “Superflex” from OAK-Mitsu
Metallurgical Factors
 Copper foils have grain structures that vary widely depending
on the manufacturing process
 My research has found that they do not behave as does bulk
copper both in the annealed and cold worked states
 Foils developed for flex circuit applications are sometimes
tailored for the type of flex and expected number of cycles
 Specific Cycling Tests have been developed to determine
fatigue properties for various common applications such as:
– Disk drives
– Cellular telephones
– Printers
Reference copper foil fatigue
characteristics (1/2 oz)
Long
Crack propagation
length
short
Crack propagation
length
Superflex copper
Is “SuperFlex” right for a
vibration application?
Interviews with OAK-MITSUI tech
support:
this material was developed for
primary use in cellular telephone
applications – large bend-to install
and moderate flexure cycles.
The last fatigue test was performed
over 10 years ago to certify to IPC
4562 grade 11
Our application sounds like a
misapplication due to the number of
cycles accumulated during our
vibration testing
They have never encountered a
similar application
Hitachi copper foil research
Crack microstructure
“RA”
“ED”
Fatigue Life - vibration
~12 Hr qualification test
Conclusion
 Rolled and Annealed copper foil is the
clear choice over electrodeposited
metallurgy for a high cycle flex
application.
Goals
 Characterize the modal frequencies.
 Examine the response to Qualification
level sine vibration 10G over 20-
2000hz.
 Look at 3 mutually perpendicular input
axes.

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Copper foil fatigue

  • 1. Copper Foil mechanical fatigue in flexible printed circuits subject to high cycle vibration 04/22/2009 Don Blanchet 3B Associates 339-234-3544
  • 2. Scope  Present information on the metallurgical structure of 2 copper foil structures used in flex circuit design for a vibration environment – RA, rolled annealed – ED, electrodeposited  “Superflex” from OAK-Mitsu
  • 3. Metallurgical Factors  Copper foils have grain structures that vary widely depending on the manufacturing process  My research has found that they do not behave as does bulk copper both in the annealed and cold worked states  Foils developed for flex circuit applications are sometimes tailored for the type of flex and expected number of cycles  Specific Cycling Tests have been developed to determine fatigue properties for various common applications such as: – Disk drives – Cellular telephones – Printers
  • 4. Reference copper foil fatigue characteristics (1/2 oz) Long Crack propagation length short Crack propagation length
  • 6. Is “SuperFlex” right for a vibration application? Interviews with OAK-MITSUI tech support: this material was developed for primary use in cellular telephone applications – large bend-to install and moderate flexure cycles. The last fatigue test was performed over 10 years ago to certify to IPC 4562 grade 11 Our application sounds like a misapplication due to the number of cycles accumulated during our vibration testing They have never encountered a similar application
  • 9. Fatigue Life - vibration ~12 Hr qualification test
  • 10. Conclusion  Rolled and Annealed copper foil is the clear choice over electrodeposited metallurgy for a high cycle flex application.
  • 11. Goals  Characterize the modal frequencies.  Examine the response to Qualification level sine vibration 10G over 20- 2000hz.  Look at 3 mutually perpendicular input axes.