Bypasses for high Currents Wirelaid® - www.we-online.de Partial high Current Solution, Technology, Applications 03.12.2014 Agenda Introduction Design Thermal Guide Views Preisvergleich, thermische Betrachtung WIRELAID vs Standard www.we-online.de Example of use Cost Comparison FAQ Seite 2 Need to know References Perspective 03.12.2014 Introduction Market requirements: Currents (300A and more) Logic (SMD, Fine Lines) Use on one single PCB www.we-online.de Seite 3 03.12.2014 Introduction Principle Use of wires to realize high current nets Power and controllers on one single PCB or layer Alternative to thick copper or Inlays @ low amount of layers Technique Welding of flat copper wires(1,4mm x 0,35mm) onto the treatment side (later inside) from standard copper foils After pressing, wires are inside the laminate, embedded in prepreg/raisin Additional cross section under a conventional copper track Outer layers keeps SMD cabability www.we-online.de Seite 4 03.12.2014 Introduction 3D Feature www.we-online.de Seite 5 Deep milling through base material Complex clearance without connectors High cross sections @ small bending radiuses(<1mm) possible Secure and fully intergated 90° high current application 03.12.2014 Introduction For more intensive introduction, please use our web archive: www.we-online.de Seite 6 Video recordings Presentationslides as pdf By the way: for all web contents 03.12.2014 Agenda Introduction Design Thermal Guide Views Preisvergleich, thermische Betrachtung WIRELAID vs Standard www.we-online.de Example of use Cost Comparison FAQ Seite 7 Need to know References Perspective 03.12.2014 WIRELAID versus Standard Customer requirement: 20A @ 20K (35µm Base-Cu) 8,9mm 0,63mm² 4,5mm 1,9mm With WIRELAID saving of 78,7% width WIRELAID F14 www.we-online.de Cross section wire Cu over wire (35µm Base-Cu) Width standard track (35µm Basis-Cu) Reduction of width 0,5mm² 1,9mm 8,9mm 78,7% Seite 8 03.12.2014 Agenda Introduction Design Thermal Guide Views Preisvergleich, thermische Betrachtung WIRELAID vs Standard www.we-online.de Example of use Cost Comparison FAQ Seite 9 Need to know References Perspective 03.12.2014 Design Guide NEU Since electronica 2014 there is the new WIRELAID Design Guide 1.2 – – – – new: Nomenclature new: Design notes for use of Wirelaid layers new: Cost comparison new: Current feeding english / french versions follows www.we-online.de Seite 10 03.12.2014 Design Guide: Nomenclature of WIRELAID Layer stack up MLn Wire@a@b....@n n = Number of layers a, b, c…: Layers with wires Outer Layer Inner Layer Example shows a multilayer with 6 layers and wires under layer 1 and 6 www.we-online.de Example shows a multilayer with 6 layers and wires under layer 2 and 5 Seite 11 03.12.2014 Design Guide: Outer layer? Inner layer? Consideration 1: More complex logic devices use SMD components like controllers or memories with small pitches. To keep the SMD layers free for fine line structures, the wires are applied in the inner layers. Requirements concerning EMC and multiple power supplies, using the innerlayers, can be implemented with standard cores and copper thicknesses. The number of layers is, compared with the normal multilayer setup, almost equal, have a look at the stackup ML6 Wire@2@5: www.we-online.de Seite 12 03.12.2014 Design Guide: Outer layer? Inner layer? Consideration 2: When cooling thru direct contact to the housing plays a roll or power semiconductors like IGBTs or D²PACs are placed directly to the outer layer, then, a Wirelaid layer with welded wire will be used. Look at the stackup ML6 Wire@1@6.: This should be the aim for more simple logic devices as well. Furthermore many vias/thru holes can be saved and thereby costs, when the power components will be placed directly onto the welding pad from Wirelaid For more simple devices it is possible to reduce the number of layers www.we-online.de Seite 13 03.12.2014 Agenda Introduction Design Thermal Guide Views Preisvergleich, thermische Betrachtung WIRELAID vs Standard www.we-online.de Example of use Cost Comparison FAQ Seite 14 Need to know References Perspective 03.12.2014 Example of Use Permanent current charge Maximum temperature Previous: After: 70 A 80C° 8 Layers, 6 Innelayers at 105µm Cu 4 Layers Wirelaid ML4 Wire@2 Cost advantage thru lower layer number and thin copper foils www.we-online.de Seite 15 03.12.2014 Cost comparison: conventional solution Initial situation A multilayer PCB with 6 layers at 105 micron copper, takes the high current part. The logic is placed at a separate fine line module, connected by PCB connectors to the main board New solution with WIRELAID Due to the possibility of fine line structures together at the assembly layers, the logic module can be completely integrated. All kind of connection technologies, as well as every other assembly costs for the module integration, can be cancelled. www.we-online.de Seite 16 03.12.2014 Cost comparison 1: PCB level 6-layer: inner 210µm / outer 70µm WIRELAID Saving from 2 layers Number of wires per manufacturing panel up to equal costs www.we-online.de Seite 17 03.12.2014 Cost comparison 2: System level Conventional solution Power PCB ML6, 105µm, logic module & connectors New solution WIRELAID PCB ML6 Wire@1 Mainboard Logic module Connectors Initials assembly Stencils AOI test Testcosts Set up costs per order Stock and logistics In practice:1/2 of the costs. Impressing as well is the high potential of savings at the Initials, which, seen absolutely, are decisive especially at lower volumes. www.we-online.de Seite 18 03.12.2014 Frequently asked questions from customer point of view FAQ WIRELAID – Everydays exemplary experiences 1. Hot spots at wire transitions? 2. How can I realize power feeds in and out? www.we-online.de Seite 19 03.12.2014 FAQ – Everydays experiences Hot Spots t wire transitions? No – – Increasing current densities Distances determined by wires and design rules Problem analysation – Thermographic analyse – Background: • Power drop at ohmic resistor – @ P = I² x R, higher current density S – Solution: Due to the high local heat capacity, not hot spot occurs (spreading) Valid relation: www.we-online.de I [A] = 9,1 [mm²] Seite 20 0,68 * ΔT [K]0,43 03.12.2014 FAQ: Power feeding through power elements Up to 50 A: SMD Power elements – – – – – over 50 A: Press-Fit Powerelements – – – – – No pad drilling Ideal for WIRELAID Standard assembling and soldering Available is reel with suction cap In- and external thread M3 or M4 Solderless, high reliable connections In- and external thread up to M10 Retention force by IEC 352-5 Respect drill spec for pressfittechnolgy! No drill into WIRELAID wires! More Infos: we-online.com/powerelements www.we-online.de Seite 21 03.12.2014 FAQ: Power feeding through power elements Press-Fit Powerelements Drill spezification: – Chemical surfaces – HAL Surface www.we-online.de Seite 22 03.12.2014 FAQ: Power feeding through power elements Press-Fit Powerelements WIRELAID wires has not to be drilled ! Cross section comparison: – Welding area at wire / Pad: ca. 1mm – Connection in plated drill: Dia 1,45mm,* Wire thickness 0,35mm Cross section drill 1,45mm, 25µm Cu plating in drill: – www.we-online.de 0,8mm² 0,6mm² 0,11mm² Seite 23 03.12.2014 Agenda Introduction Design Thermal Guide Views Preisvergleich, thermische Betrachtung WIRELAID vs Standard www.we-online.de Example of use Cost Comparison FAQ Seite 24 Need to know References Perspective 03.12.2014 Thermal View (TRM Software © Adam Research) Servo driver 75A Layout Wirelaid ML4 Wire@2@3 IL70µm, AL 35µm Cu Base Servo driver75A Layout conventionel ML6, je 70µm Cu Base www.we-online.de Seite 25 03.12.2014 Thermal View (TRM Software © Adam Research) Setting the simulation area after : • Current density S • Electrical conductivity σ (Sigma) • Thermal conductivity λ (Lambda) • Layer Stack Up www.we-online.de Seite 26 03.12.2014 Thermal View (TRM Software © Adam Research) Simulation result, Driver Servo Motor 75 A Layout WIRELAID Tmax 33,8°C Real IR Masuring Driver Servo Motor 75A Layout conventionel Tmax: 35,3°C www.we-online.de Seite 27 03.12.2014 Thermal View (TRM Software © Adam Research) Real IR Measuring Driver Servo Motor 75 A Layout Wirelaid Tmax: 27,4°C Due to the WIRELAID setup, at better performance, a core (2layers) and base copper could be saved www.we-online.de Seite 28 03.12.2014 Thermal View: Demonstrator left: Multilayer 6 Layer each 105µm Cu right: 2 LayerML2 Wire@1@2 each 35µm Cu, Wires F14 Result at 50A: Equal heating, measured with OPTRIS IR Camera Kindly supported by Optris, Berlin www.we-online.de Seite 29 03.12.2014 The following is a short survey Which statement applies to WIRELAID? www.we-online.de Seite 30 03.12.2014 Agenda Introduction Design Thermal Guide Views Preisvergleich, thermische Betrachtung WIRELAID vs Standard www.we-online.de Example of use Cost Comparison FAQ Seite 31 Needs to know References Perspective 03.12.2014 Need to know: Manufacturing of WIRELAID foils Manufacturing steps current stage of evolution : available are base materials and wires with adapted surfaces and fillings in proven combinations up to 180°C PCB working temperatures www.we-online.de Seite 32 03.12.2014 Need to know: Application range of WIRELAID The WIRELAID current capacity has no typical lower limit Also small, area sensitive devices can benefit Present applications realsizes up to 300 A The upper boarder of the currents limit only economic aspects The upper limit is only fixed at economic borders Any Questions? For more informations concerning higher currents, please contact directly our product management: [email protected] www.we-online.de Seite 33 03.12.2014 Need to know: Supplier base: WIRELAID License partners 5 licensed german manufacturers 2 asian manufacturers for high volumes Currently negotiations with two more potential asian partners Welding machines: – 6. Evolution variant for extended use with other manufacturers Series production of various applications in the field of 10k / y www.we-online.de § Seite 34 03.12.2014 References: WIRELAID Qualifications HTG Storage: Bosch Norm BV Y273 R80029 1000h at 140°C Humidity climate: IPC TM 650 1000h bei 85°C and 85% RH TWT: – – Corrosion: IPC612 B / TM 650 Testing for silver migration Permanent shock: EN 60068 2-29 100000 Impulses (11ms) at max. 50G Delamination: IPC 6012B – IPC 6012 B, 1000 Zyklen BV Y273 R80029 Solder bath test 10s at 288°C UL: Kategorie ZPMV2/8 – Full Recognition with MOT and CTI in work www.we-online.de Seite 35 03.12.2014 References: WIRELAID Application Winderergy Pitchadjustment Previous: ML6 After: ML4 wire@2@3 www.we-online.de Seite 36 03.12.2014 References: WIRELAID Apllication Industry AC Servo Amplifier Permanent current charge 50 A Maximum Temperature 80C° Previous: 2 PCBs, 6 Layer 70µm After: 1 Leiterplatte, ML6 Wire @1 + 3D Benefit: Manufacturing, assembly, test, stock and loss of single modules and PCB connectors www.we-online.de Seite 37 03.12.2014 References: WIRELAID Application automotive Vehicle Components Endurance Test Bench Previous: Combination of flat wire / connector PCB, 2 PCBs ML4 After: 1 PCB, ML4 Wire @1 + 3D Benefits: Eliminating all manual operations, fully integrated PCB connection, more usable PCB space www.we-online.de Seite 38 03.12.2014 References: WIRELAID Application E-Bike Drive controll, charging electronics (picture is exemplary) Previous: ML6 70µm/4x210µm/70µm After (in development): ML6 Wire @2@3@4@5, each 70µm Benefits: Reduction to 70µm Cu base on all layers, PCB with smaller dimensions, easy to manufacture www.we-online.de Seite 39 03.12.2014 Perspective: Passive cooling Measurement 1 without WIRELAID ML4 Heating chip of Tu = 20 ° C to Tmax = 55 ° C, at nominal power dissipation (16,5W / cm²)? 15s image after operation www.we-online.de Measurement 2 with WIRELAID ML4 wire @1@4 Heating chip of Tu = 20 ° C to Tmax = 38 ° C, at nominal power dissipation (16,5W / cm²) Image after 15s operating Note the significant heat spreading over the horizontal wires and the lower temperature after the measuring time Tmax Much improved situation, and NO hot spot spot Seite 40 03.12.2014 Perspective: Powerflex Embedded wires through „Semiflex-Area“ Combination buckling and bending area Signals and currents transported over buckling areas We have now arrived at the end of the webinar. You see, WIRELAID is an interesting tool in electronic development and design. I hope you were able to gain new knowledge or extend existing ones. www.we-online.de Seite 41 03.12.2014 Thank you for your attention www.we-online.de Seite 42 03.12.2014