Your Reliable Automotive PCB Manufacturer in China

There are different reasons why automotive PCBs are vital to have in vehicles.

• Automotive PCBs are enhancing the performance and functionality of the vehicle.
• Such PCBs are aiming to save fuel and reduce tail gas. These are also helping in transforming the vehicles from conventional fuel to pure electrical power.
• Automotive PCBs are improving the security features of vehicles. Such PCBs are playing a vital role in the automation of vehicles resulting in lesser accidents, anti-theft, monitoring, and cameras, etc.
• PCBs are also bringing comfort with the addition of air-conditioning systems, audio, and video entertainment system, and tracking system,s, etc.
• The autopilot which is also known as auto driver is a system of modern vehicles which is almost entirely based on a set of PCBs interconnected together performing a collective function. This is a highly sophisticated system of electronic equipment which is functioning behind the curtain and producing the best outcome. Such PCBs are preprogrammed and have sensors for sensing and collecting data and make the right decision at right time. The autopilot system is detecting on-road obstacles and is taking braking decisions all by itself without any assistance from the driver.

The PCBs can be considered as the backbone of the automotive industry when it comes to its electrical and electronic components and their functioning. Different types of PCBs are used in the automotive industry.

1. Flexible PCBs

The flexible PCB is one in which the electronic components are assembled onto it through mounting over a plastic substrate of flexible nature. The plastic substrate can be of different types such as polyester film, polyimide, and peek for conduction of electricity. Such PCBs can be easily twisted, bent, turned, and moved to any of desired shapes.

Automotive PCB: Flexible PCB

2. Rigid PCBs

The rigid PCBs are the ones on which electronic components are installed over stiff board. Such PCBs cannot be twisted, bent, and folded because such PCBs have stiffeners like FR4 material. The use of such PCBs is in display monitors and other screens of the vehicle.

Automotive PCB: Rigid PCB

3. Flexible-Rigid PCBs

The flexible-rigid PCBs are one on which different components are mounted over both rigid and flexible boards. Such PCBs are comprising of various layers of circuits having an external or internal attachment to one or more rigid boards. Such PCBs are used for the lighting system of vehicles.

Automotive PCB: Rigid-flex PCB

4. HDI PCBs

HDI PCBs are having a higher density per unit area of wiring over the boards when compared to other PCBs. These are having smaller vias and capture pads along with spaces and finer lines with higher connection density for pads.

Automotive PCB: HDI PCB

5. LED PCBs

LED PCBs are consisting of a chip which is producing light whenever an electrical current is passing through it. The major material of such PCBs is aluminum which is a brilliant conductor of electricity and heat.

Automotive PCB: Rigid PCB

6. Copper PCBs

The heavy copper PCBs are ones having more than 3 ounces of copper through the board’s inner and outer layers. Such PCBs are assisting in the elimination of the complex configuration of wiring. These are also increasing resistance against the capacity of current carriage and thermal strains.

7. Metal Core PCBs

Metal PCBs are depending on aluminum or copper as their major core with its lowered side behaving like a heat sink. The metallic core is a very good conductor of heat and is thus eliminating heat from vehicles.

Automotive PCB: Metal Core PCB

8. Single-Sided PCBs

Single-sided PCBs are having all of the components installed onto a single side. Simply stating that components are all on one side and conductive material is on another side.

9. Double-Sided PCBs

Dual or double-sided PCBs are also known as double-sided plated-through PCBs or DSPT. Such PCBs are used in advanced vehicles only. These are dependent on vias which are allowing closer routing traces for alternation among the top and bottom layers.

10. Multi-Layered PCBs

The multi-layered PCBs are ones having more than 2 layers on board. Such PCBs are having greater than 3 materials at their center. These are allowing easy control and incorporation of features of impedance having higher density and flexibility.

There are numerous features of automotive PCBs assisting vehicles in their operation.

1. Suitability for Complex System

The vehicles have numerous complex systems which continuously face different severe challenges such as high temperatures, oil, dirt, and pressure, etc. The PCBs have dedicated features that are able to withstand extreme scenarios and allows luxurious and comfortable drive.

2. Withstanding High Temperatures

The automotive PCBs are capable of withstanding higher temperatures. These work efficiently in both extreme low and high temperatures. The material used in these PCBs is able to tolerate extreme fluctuation of temperatures.

3. Chemical Resistant

The automotive PCBs are highly resistant to chemicals like organic solvent, bases, acids, and adhesives, etc. This is why automotive PCBs last longer than an ordinary one.

4. Reliability

The automotive PCBs material is stronger and has a longer life. The reliability of these PCBs makes them well-suited to be used in the automotive industry which can withstand harsh conditions without affecting its functioning.

5. Adaptability

The vehicles are driven in different places and various terrains with diverse characteristics when the environment is concerned.

The automotive industries are making sure to use PCBs able to adapt to dissimilar environments.

6. Dirt Resistant

Dirt is often accumulated onto vehicles. Therefore, the PCB system of the vehicle is needed to be dirt resistant enough to avoid short circuitry and malfunctioning.

Different laminations are used by manufacturers to keep dirt away from PCBs.

Different applications of vehicles are using automotive PCBs. It can be stated that when it comes to applications, PCBs can be considered as the backbone of the electrical system.

Automotive PCBs are performing various functions of vehicles.

Different Automotive PCBs

The following is the list of the main applications of automotive PCBs.

• GPS kit.
• ECU modules.
• ECL modules.
• Braking system (Anti-lock).
• Displays (Digital).
• Sensors of transmission.
• Radar system.
• Audio and stereo components.
• AC/DC converters.
• Engine controls.
• Engine timing system.
• LED system.
• Occupant detectors.
• Power distribution board.
• Diagnostic system.
• Instrumentation
• Infotainment system.
• Airbag working system.
• Obstacle detection.
• Emergency assist system.

The process of automotive PCB assembly is almost the same as that in other industries.

First of all, design software acquisition is necessary to have.

The design software is capable of assisting incomplete assembly and production phase after creating a prototype.

The design software is having all of the key features which are necessary for the creation of a prototype.

Different software is available in the market e.g., dip trace, eagle, and proteus, etc.

1. Understanding specifications of PCB

Dimensions are needed to be specified along with material type, layers number, finishing of the plate, the thickness of the board, and impedance, etc. Apart from the mentioned parameters, castellated holes, silkscreen, solder mask, minimum pitch, holes size, and spacing parameters can also be mentioned.

2. Checking Design Rules Violation

The next step is checking whether or not there are any design rule violations. Through design software assistance, all such violations can be troubleshot and rectified.

3. Generation of Gerber Files

The design software is helping in the generation of the main blueprint of the required PCB. After the blueprint is created, Gerber files are also needed to be created for ensuring the right order of all processes.

4. Stacking Up Documents

When Gerber files are ready, it is then time for the creation of a stack up for the documentation. Everything must be arranged in a proper manner and all layers must be labeled in accordance. After that, the manufacturers are creating a prototype and then perform a different test to check its functionality.

When the prototype of the automotive PCB is ready, it is then time to set hands on the production. The Assembly process is the main step in mass production. However, before proceeding to the assembly procedure, it must be ensured that the prototype is working in perfection and all of its functions are adhering to the requirements. The assembly process has different phases described below.

1. Photoengraving

This is the process where a photomask or simple mask is combined with the chemical etching. This process is subtracting copper areas from the main substrate of the printed circuit board. After that through a photoplotter design was used in combination with a certain PC. B CAD program, a photomask is produced. A laser printer can also be used for making photomasks.

2. Lamination

As far as the multi-layered automotive PCBs are concerned, one of the most necessary requirements is to have bounded layers. The lamination process is used for bonding different layers together. Lamination is also covering and securing the sensitive circuit from external agents like dirt and other environmental factors. This process is resulting in a safe and good quality automotive PCB.

3. Drilling

The multi-layered automotive PCBs have a requirement of connecting their layers together with each other.

This function can be achieved through mere drilling the vias or holes throughout the different layers of PCB.

The layers can be drilled through the drilling machine very easily.

The specifications are needed to be entered through a computer and the rest of the task is achieved through the automatic drilling machine itself.

4. Solder Plating

After drilling, all of the components can be mounted onto the PCB’s substrate and then connected with other layers with the help of vias.

In such a case, soldering is to be done with pads and lands where the electronic components are needed to be connected.

As a matter of fact, bare copper soldering is not an easy task; therefore, surface plating is required with a material that is easily solderable. Tin has been extensively used for this purpose.

However, to comply with RoHS, now nickel or gold is used for plating.

5. Circuit Board Testing

After the above-mentioned steps are concluded, it is now time to test the produced printed circuit board.

The testing phase is happening before the connection of other components or parts to the PCB itself.

There are different methods for testing the produced PCB such as nail tester and flying probe tester etc.

All rules of PCB manufacturing are to be followed in order to get a fully functional PCB.

The automotive PCB future is very bright as the advancement in technology is growing with each passing day.

The automotive printed circuit boards are of great importance in almost all types of vehicles.

Almost all types of printed circuit boards are used in the automotive industry.

However, flexible, LED, and multi-layered PCBs are abundantly used.

The flexible PCBs are even used in the back windshield of vehicles in order to limit fog accumulation on it.

Similarly, in recent times multi-layered PCBs found abundant use in high-tech vehicles produced by giant auto manufacturers.

Most of the multi-layered PCBs are used in self-driving or driverless vehicles.

It can be concluded that automotive PCBs have a critical role play in the auto industry and their significance will increase with time.