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PCB Stiffeners for Flex PCBs

In the design of modern electronic products, flex and rigid-flex circuit boards (PCBs) are widely used because of their lightweight and flexible characteristics. However, flex circuit boards are easily deformed or damaged by mechanical stress during welding, assembly and long-term use. Therefore, an element that can improve the structural strength and stability of the circuit board is needed, and thus PCB stiffener appears. This time, this paper will carry on an in-depth discussion of PCB stiffeners, including the definition of PCB stiffeners, main functions, applications, advantages, and design points.


What is a PCB Stiffener?


PCB Stiffener is a material used to increase the structural rigidity and support strength of flex PCBs and rigid-flex PCBs, which not only helps to improve the mechanical properties of circuit boards, but also enhances the assembly efficiency, making the boards more stable when carrying heavier components. Especially in flex PCBs, it can provide additional mechanical support to avoid deformation or damage to the PCBs during operation, welding and use. Overall, PCB stiffener plays an important role in improving the stability and durability of the circuit boards.

 

Why Do Flex PCBs Need Stiffeners?

 

A flex PCB requires a stiffener primarily to enhance mechanical strength and stability. Since the material of a flex PCB is very thin and can be bent and folded, certain key areas often need additional support and protection to maintain integrity during use. It is commonly used in welding areas, connector ports, heavy component areas, and other areas where strength needs to be increased. For example:

 

1. Welding area:

 


Flex PCB will be deformed during welding, resulting in weak welding points and affecting the stability of electrical connections. At this time, it is necessary to add a PCB stiffener board in the welding area, especially the welding point of the connector or component, to prevent the circuit board from warping or damage due to welding heat and operating force, and improve the reliability of welding.


2. Connector area:

 


The connector area of the board will be inserted and removed repeatedly, and the stress generated at this time will cause the flex board to bend or tear, and even cause the connector to fall off. However, adding a PCB stiffener in these areas can effectively prevent circuit board damage caused by repeated insertion or use of the connector.

 

3. Heavy components area:



For heavier components, if there is no PCB stiffener support, the flex area will not be able to withstand the weight of the component, resulting in bending or even damage. Therefore, for areas where heavier components or components need to be installed, a PCB stiffener needs to be added to provide additional support and disperse the pressure of heavy objects, preventing flex PCB deformation.

 

After understanding why flex PCBs need stiffeners, let's take a look at parameters of PCB stiffeners.


Parameters of PCB Stiffeners


Common Flex PCB Stiffener Materials


PCB Stiffener materials are rich, common materials such as FR4, polyimide (PI) and metal materials.


Stiffener Material

Advantages

Disadvantages

FR4 Stiffener

-Good heat resistance, suitable for high-temperature soldering

-Easy to process, suitable for cutting, drilling, and shaping

-Dimensionally stable, provides reliable support

-Relatively heavy, adds weight to the PCB

-Not suitable for high-frequency applications

Polyimide (PI) Stiffener

-Lightweight and highly flexible, suitable for applications requiring frequent bending

-Excellent heat resistance, ideal for extreme temperature environments

- High chemical stability, resistant to chemical corrosion

-Higher cost, increases manufacturing expenses

-Limited electrical performance in high-frequency applications

Aluminum and Stainless Steel Stiffeners

-High mechanical strength, ideal for high-load applications

-Good thermal conductivity, suitable for heat dissipation

-Durable, ideal for long-term use in harsh environments

-High density, adds significant weight

-Difficult to process, increases manufacturing complexity and cost


In some specific applications, PCB stiffener busbar is also used, which not only enhances the rigidity of the circuit board, but also can be used to conduct current.

 

Stiffener Thicknesses

 

The thickness of PCB stiffener varies with different materials, and the appropriate thickness needs to be selected according to the specific application and support requirements.

 

Stiffener Material

Typical Thickness Range

Applicability

FR4 Stiffener

0.2mm - 1.6mm

Suitable for areas requiring high mechanical strength, such as connector and soldering areas;

Polyimide (PI) Stiffener

0.05mm - 0.5mm

Ideal for lightweight areas that need to retain flexibility, such as frequently bent sections;

Aluminum Stiffener

0.5mm - 2.0mm

Suitable for high-strength and high-heat dissipation applications, such as high-current areas, but significantly increases PCB weight.

Stainless Steel Stiffener

0.3mm - 1.5mm

Used in areas requiring high mechanical strength, suitable for high-load applications, especially in harsh environments, providing durability but adding thickness to the PCB.


Stiffener Performance Comparison


Stiffeners of different materials have great differences in performance; please see the following table. This form will help you choose the most suitable stiffeners material.


Performance Indicator

FR4 Stiffener

Polyimide (PI) Stiffener

Aluminum Stiffener

Stainless Steel Stiffener

Mechanical Strength

Moderate, suitable for general support

Moderate, suitable for high-flexibility applications

High, ideal for high-load scenarios

Very high, suited for extreme strength requirements

Weight

Moderate, adds overall PCB weight

Lightweight, ideal for weight-sensitive applications

Relatively heavy, not ideal for weight-sensitive applications

Relatively heavy, increases PCB weight

Heat Resistance

Excellent, suitable for high-temperature soldering

Exceptional, suitable for extreme high-temperature applications

Excellent, with good heat dissipation properties

Excellent, suitable for high-temperature and high-stress environments

Flexibility

Low, high rigidity

High, suitable for frequently bent areas

No flexibility, suitable for rigid areas

No flexibility, ideal for high-strength support areas

Chemical Resistance

Good

Excellent, suitable for harsh chemical environments

Moderate, prone to corrosion

Excellent, highly corrosion-resistant

Thermal Conductivity

Low

Low

High, suitable for applications with high heat dissipation needs

Moderate, suitable for applications needing both heat dissipation and mechanical strength

Cost

Moderate

Higher, increases manufacturing costs

Higher, suited for high-performance applications

Higher, ideal for high-strength and high-durability needs


 

Multi-layer PCB Stiffeners


Some designs require multi-layer PCB stiffeners or a combination of multiple materials, in which case you need to consider several points to ensure the reinforcement effect and the performance of the overall board:



Material Compatibility:


Different materials have different coefficient of thermal expansion (CTE) and will expand or contract at different rates under temperature changes. Therefore, when combining a variety of materials, we should choose materials with similar thermal expansion coefficients, so as to avoid delamination, warping or cracking caused by temperature changes.

 

Interlayer Bonding:


The bonding between layers is very important for the multilayer stiffeners. Good interlayer bonding ensures that the reinforced plate remains intact under mechanical stress. Therefore, we recommend the use of a special high-strength adhesive between the multi-layer stiffeners (the heat resistance and anti-aging of the adhesive should meet the requirements of the use of the circuit board).

 

Thickness:


The number of PCB reinforcement boards is large, and the board will inevitably be thicker. Therefore, for the multi-layer PCB stiffener, we must control the thickness of each layer to ensure that it meets the thickness limit and assembly requirements of the circuit board and can provide sufficient support without affecting the overall flexibility of the flex PCB.

 

Weight:


In flex PCB or rigid-flex PCB, weight can affect the bending ability and flexibility of the board. Therefore, in the application of multi-layer stiffeners or to use the board for lightweight applications, you should choose lightweight materials, such as polyimide (PI) or thin FR4.

 

Placement of Stiffeners

 

In a Flex PCB, the position of the stiffener has a significant impact on the overall performance and reliability of the board. Common placement locations include:

 

Top or bottom layer: The top layer of reinforcement can increase the tensile strength when the board is bent, while the bottom layer of reinforcement can increase the compressive strength. For flex circuit boards that need to be bent frequently, single-sided or double-sided reinforcement plate placement can effectively prevent cracks or deformation.

 

Designated areas: like connector areas, welding areas or areas where heavy components need to be installed, these areas are subjected to greater mechanical stress, reinforcement plates are needed to improve the durability and stability of the board.


Design Principle of PCB Stiffeners


Follow the following guidelines to ensure the effective integration and functionality of the reinforcement board:

 

Layer position: The reinforcement board should be as close as possible to the core layer of the flex circuit board to ensure maximum support. (For multi-layer stiffeners, we should consider the overall rigidity and flexibility of the balance.)

 

Layer bonding: The reliability of layer bonding is directly related to the long-term stability of the board, so it is recommended to use high-strength, heat-resistant adhesives to avoid separation or displacement between layers.

 

Outline design: The outline of the reinforcement board should match the shape of the circuit board to avoid sharp corners or irregular edges, so as to avoid stress concentration leading to damage to the reinforcement board or circuit board. (The smooth contour design can better adapt to the bending needs of the circuit board and extend the service life.)

 

Installation characteristics: We can design the reinforcement board to be easy to install and remove according to the application requirements. (For some areas that need to be welded, the reinforcement plate can be designed to be temporarily disassembled for easy repair and replacement.)

 

Flex transition: When designing the transition between the reinforcement plate and the flex area, it should be ensured that the transition area has appropriate flexibility. (Avoid cracks or breaks due to rigidity differences.)

 

Conclusion


In summary, the PCB stiffener plays a crucial role in the flex and rigid-flex PCB, which not only enhances the mechanical strength of the circuit board, but also effectively improves its stability and durability. I hope this article can provide you with a clear design reference so that you can better choose and configure the reinforcement board in practical applications. If you have any questions, please feel free to contact us!

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