Research Design Issues

1
Research Design Issues

• Scope of work to be done
• Work Underway at Loughborough

2
Scope of Work
3
Information Tabled So Far

• Draft FPC specification tabled by Yazaki
• test acceptance criteria yet to be determined
• Materials choices identified by GTS
• Processes choices identified by Loughborough

4
Basic Design Choices

• Materials
• base film ?2 (PEN or PET)/adhesive ?2 (PET/PU or
  epoxy)/coverlayer ?2 (film or ink)
• Processes
• subtractive technology/additive
  technology/combined technology/selective
  enhancement/PTH
• Main conductor probably ED copper

5
Tests

• Base laminate properties ?12
• Mechanical performance ?5
• Electrical performance ?5
• Environmental performance ?6
• Design/Test matrix potentially very large!

6
Work Underway at Loughborough
7
Test Methods/Standards

• Identification of further applicable
  tests/standards
• Obtaining of full copies of test methods
  /standards

8
Test Matrix for Basic Design Choice

• Reduce test matrix size by
• Assessing relevancy of tests
• Identifying incompatible materials/process
  combinations (eg alkaline etch/acrylic adhesive)
• Identifying representative materials/process
  combinations
• Manufacture test coupons
• Conduct tests

9
Representative Circuit Layout

• Design representative circuit layout from wire
  harness circuit diagram (to be supplied)
• Incorporate fine line areas
• Manufacture circuit to as large a size as
  possible
• Assess against cockpit, door (to be supplied)

10
Requirements

• Copies of standards (Yazaki/Daewoo/Loughborough)
• Test acceptance criteria (Yazaki/Daewoo/Loughborou
  gh)
• Harness circuit layout (Yazaki)
• Cockpit, door (Daewoo)

11
Conclusions

• Results of Basic Design Choice tests and cost
  modelling will be used to choose materials
  /process for prototypes
• Manufacture of representative circuit layout will
  give early identification of problems with
  scaling up