Cicorel SA Printed Circuits Manufacturing Out of Standards

cicorel SA

Printed Circuits Manufacturing

Out of Standards

LECC Heidelberg 14 September 2005 cicorel SA

Out of Standards Printed Circuits Manufacturing

• A User :

CERN 1211 Geneva 23 Francois Vasey, [email protected]

• A Manufacturer :

Cicorel SA, Route de l’Europe 8, 2017 Boudry (Swiss organization) Anne-Sophie Golsong-Roosdorp [email protected] Hans Wyss [email protected]


• Real facts in 3 specific projects

• Consequences as result from different perspectives (user and manufacturer)

• Manufacturer recommendations

Out of Standards Printed Circuits Manufacturing


Readout electrodes for the Atlas electromagnetic calorimeter

These 7000 electrodes in a size of 0,8 x 1,8 m had as main characteristics :

• Large flexible circuits etched on copper-polyimide laminates

• 3 layered circuits needing impeccable bonding over large surfaces in an autoclave

• Stringent dimensional tolerances (~ 0,2 mm over 1,8 m) for etched images and mechanical cut-outs

• Serigraphy of resistive ink over large surfaces

• Fault-free electrical properties (high voltage and connectors)




User• Based on prototypes’ production

• Costs : only 1 supplier for base material

• Simplified qualifications

• 1 source = 1 contact

• 1 type of product : developer’s knowledge and requests (Radiation properties).

Manufacturer

• Larger format : Production’s requirements ≠ selection of the material supplied

• Quality needed not provided by selected supplier

• Doubts in solution and in feasibility, doubts in technology, doubts by engineers

Consequences• Both developer and manufacturer agree on specification criteria

• Homologate and certify materials and suppliers

• Consider long delay and loss of time and money

• Manage production quality and logistic. Planning.



The hybrid to be delivered consists of a 6 layer copper/polyimide flexible circuit, laminated onto a carbon-carbon substrate.

It is equipped with SMD components and with ASICs which are wire bonded

ATLAS SCT Endcap Hybrid K5.2 Assembly


K5.2 THERMAL DRAIN


K5.2 Hybrid AssemblyUser

• Need of thermal drain

• Use of new technology, material Carbon, best technological features for thermic and functionality aspects

• Complex format

• Test data record

Manufacturer

• Complex format to be easily metalized

• Fragility of selected material

• Focus on an automated solution

• Interface and requests between several involved industries (PCB manufacturer and assembler)

Consequences• Manufacturer to understand with anticipation the needs and application

of user for the data record.

• Define a project leader.

• Adapt manufacturing constraints and think of final solution.

• Consider industrialization. Time for Engineering and Conceptual phase.


Quench Heaters for LHC superconducting magnets

The Quench Heaters consist in partially copper-plated austenitic stainless steel strips sandwiched between electrically insulating (Polyimide) foils with electrical and mechanical properties so as withstands high voltages, low temperatures, high compression forces and ionizing radiation





User

• Heating capability

• Base material to be homologated under specific conditions

• After several lots : new specifications on the stainless steel

Manufacturer

• No possibility to fulfill all Quality tests on stainless steel

• Specifications ≠ Standard

• Approval of manufacturing lots causes delays

• Delivery times are not respected

Consequences• Specifications are adapted

• Manufacturer works in defined conditions but faces performance and quality challenges

• Assure contractual conditions

• Make attentive to best case, worst case at an early stage


Manufacturer Recommendations

• Technology driven projects should involve early, a team of experts, where each step of realization and manufacturing are represented.Research-Development (with different industries)-Product management-Testing-Implementation.

• Define a team with a project leader, open and multi skills

• Always think best case, worst case. Find agreement with all parties involved.

• Be aware that a theoretical solution needs an industrializing expertise and consideration


Manufacturer Recommendations

• Consider intermediary Quality controls in manufacturing processes (quick failure reactions, statistics, preventive actions)

• Consider time for prototypes and corrective actions before definitive launch

• Guarantee base material continuity standard

• Maintain constant communication and working teams

Documents

Cicorel SA Printed Circuits Manufacturing Out of Standards