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If you have any needs, please feel free to contact China Chaosheng Electronics Company. Please contact us as follows:
whatsapp：+8613528819118
Skype live: pcb-fpcb88@163.com
E-mail : sales@chaoshengpcb-fpc.com
Contact: Mank. Li
China Chaosheng Electronic Sensor Fused Screen Ultra Large and Wide Flexible Circuit Board FPCSpecial Introduction to Rigid Flex PCB (FPC) Products for Automotive Standards
Multilayer Flexible FPC / Multilayer Flexible Printed Circuit
2. Rigid-Flex PCB / Flex-Rigid PCB / Rigid-Flex FPC（ RFPC）
3. Multilayer Rigid-Flex Board、Anylayer HDI Rigid-Flex PCB
4. Flexible Multilayer Printed Board、Build-up Flexible PCB
1、 Overview of Enterprises and Qualifications
China Chaosheng Group is deeply engaged in the intelligent manufacturing of high-end PCBs, FPCs, HDI arbitrary order boards, aluminum based thick copper plates, and optical module carrier boards. The Zhejiang Kunying Flexible Soft Board Factory is a production base for automotive electronic FPC specifically designed for the group. It has independently established a vehicle grade dust-free dedicated line and strictly implements the IATF16949 automotive industry quality management system throughout the entire process. The company has implemented five core automotive tools: APQP, PPAP, FMEA, MSA, and SPC. The products meet the highest reliability level of IPC-6013 Class3, AEC-Q200, ISO 16750 automotive electrical environment standards, and can match ISO 26262 functional safety ASIL-B/D level requirements. They are suitable for new energy electric vehicles, autonomous driving ADAS, and intelligent vehicles. The cockpit provides rigid flex flexible circuit boards that can be directly certified for on-board use, achieving the localization and replacement delivery of on-board core circuits.
2、 Product Structure Principle
The onboard rigid flex PCB (FPC) adopts an integrated compression molding process, seamlessly connecting the rigid and flexible areas
1. Rigid hard board area : High Tg temperature resistant and low water absorption FR-4 automotive grade board is selected for surface mount control chips, power devices, connectors, etc IGBT、 Capacitors and resistors are welded and fixed, resistant to thermal deformation, vibration and impact, and capable of carrying high-power and high-speed signal components;
2. Flexible bending area :
Using
car mounted high-temperature resistant non adhesive PI copper-clad laminate FCCL ,
it can be three-dimensional shaped and repeatedly twisted and bent, and is compatible with active interconnection positions such as door pivot, camera flipping mechanism, battery pack shaped inner cavity, screen pivot, etc;
3. Stress relief transition zone * *: Exclusive rigid flex interface buffering and compression process, matched with substrate CTE thermal expansion coefficient, to prevent delamination, bursting, and copper foil fracture under high and low temperature cycles. The integrated molding eliminates a large number of external wiring harnesses and connectors, greatly reducing the risk of single point failure in bumpy vehicle environments.
3、 Core technical parameters of vehicle specification level (Kunying Factory production standard)
（1） Process capability
1. Layers: 2-12 layers of automotive grade soft hard bonding board, supporting any order of HDI blind buried holes, resin plug holes, and laser controlled deep milling processes;
2. Fine wiring: minimum line width and spacing of 3mil/3mil (0.075mm), minimum laser blind hole of 0.1mm, interlayer alignment accuracy of ± 0.03mm;
3. Plate thickness and bending: The thinnest part in the flexible zone is 0.05mm, with a dynamic bending life of ≥ 200000 times without breaking, and a minimum bending radius of up to 5 times the plate thickness;
4. Copper thickness specification: The signal layer is 1/2OZ, and the high-power area of the power battery/electronic control can be made of 2-3OZ thick copper to carry high current loads;
5. Surface treatment: automotive grade immersion gold ENIG, immersion palladium gold, thick gold, anti oxidation OSP, resistant to oil stains, coolant, and cleaning agent corrosion;
6. Special process: It can be used as a whole board shielding layer, precise control of differential impedance, Pairuilin coating moisture-proof insulation, and milling cutting of irregular shapes.
（2） Strict reliability and hard indicators for onboard vehicles (core competitiveness)
1. Stable operation over a wide temperature range**
The working temperature ranges from -40 ℃ to 125 ℃, and can withstand over 1000 cycles of high and low temperature shock. It can withstand high temperature exposure in the cabin and extremely cold environments in winter, and thermal expansion and contraction will not cause circuit cracking or interlayer peeling;
2. Super strong seismic and dynamic impact resistance**
Through 20g random vibration and mechanical impact durability testing, it can perfectly cope with vehicle bumps, chassis vibrations, and engine resonance scenarios. The long-term driving contact impedance fluctuation is ≤ 0.5%, eliminating virtual connections and signal interruptions;
3. Corrosion resistance to complex media in vehicles**
Resist the erosion of brake oil, antifreeze, electrolyte, rainwater moisture, and car wash chemicals, with an insulation resistance of ≥ 10 ¹² Ω, and excellent moisture and mold resistance, as well as electrochemical migration resistance;
4. High speed signal integrity guarantee**
Multi layer shielding structure+differential impedance control, low dielectric loss, supports high-speed signal lossless transmission such as LVDS, Ethernet, PCIe5, etc., meeting the big data transmission needs of 77GHz millimeter wave radar and car high-definition cameras, without interference or frame loss;
5. Lightweight weight loss advantages**
Compared to traditional copper wire harnesses, it reduces weight by more than 60%, helping to reduce battery pack weight and overall vehicle weight, indirectly improving the range of new energy vehicles.
4、 Application scenarios for the entire vehicle series
（1） New Energy Vehicle Three Electric Core System (Main Large Batch Category)
1. BMS battery management system with software and hardware integrated FPC**
The power battery pack includes an integrated board for collecting cell voltage and temperature, with flexible sections that fit the irregular arrangement space of the cells. The rigid end integrates a sampling chip and protection circuit, replacing complex wiring harnesses to accurately monitor the status of each energy-saving cell, ensuring safe charging and discharging. It is widely used in CTP/CTC battery solutions;
2. Vehicle electronic control unit**
Motor controller MCU, on-board charger OBC, DC-DC converter internal power+signal integrated rigid flex board, rigid area carrying power devices, flexible area with internal three-dimensional wiring, reducing the volume of the electronic control box and improving heat dissipation performance.
（2） ADAS autonomous driving perception system (high-precision high-end product)
1. The soft and hard combination plate of the panoramic car camera and the front monocular/binocular camera flipping module is repeatedly bent at the pivot to ensure stable output of driving images;
2. 77GHz millimeter wave radar and LiDAR domain controller interconnection board, multi-layer HDI high-density wiring, low loss transmission of high-frequency signals, meeting L2-L4 level autonomous driving safety requirements;
3. The roof perception fusion domain controller has an internal three-dimensional interconnected rigid flex plate, which uses flexible segments to fit the installation space of the roof surface.
（3） Intelligent cockpit and human-machine interaction system
1. The curved central control screen, full LCD instrument panel, and front passenger entertainment screen are driven by a combination of soft and hard FPC, which is compatible with screen flipping and folding structures to achieve narrow border integrated display;
2. HUD head up display, seat memory adjustment module, steering wheel multifunction buttons, internal interconnection board of door and window lifting control module;
3. The car's ambient lighting and adaptive headlight LED drive rigid flex joint plate are compatible with the layout of the headlight's irregular housing.
（4） Vehicle Control and Chassis Electronics
BCM body controller, electronic handbrake module, chassis sensor harness adapter board, charging port electronic control signal connection board, etc.
5、 Compared to the core advantages of traditional wire harness+split PCB solutions
1. Significant upgrade in safety and reliability**
Integrated molding replaces the splicing scheme of "hard board+FPC+connector+wire harness", reducing solder joints and connection failure points by more than 60%, eliminating the risk of connector loosening and needle detachment under vehicle vibration, and meeting the zero failure requirements of automotive safety;
2. Ultimate utilization rate of vehicle space**
Three dimensional wiring at any angle can be embedded in equipment gaps, curved shells, and shafts, reducing the internal space of the whole machine by 40% -50% and facilitating modular design of the host factory structure;
3. Improve the efficiency of vehicle assembly
Single board direct buckle installation reduces the process of wire harness wrapping and terminal crimping, lowers the manual assembly cost of the host factory, and is suitable for automated assembly line assembly;
4. Long term full lifecycle cost optimization
The car grade material has a super long service life of 15 years, with an extremely low failure rate. The cost of after-sales repair is much lower than traditional wiring harness solutions, which can directly meet the PPAP reporting and component traceability requirements of car companies.
6、 Factory production capacity, quality control, and delivery assurance
1. Independent car specification dust-free production line
Independent production of automotive dedicated lines with a cleanliness level of 10000, strict control of micro short circuits and poor insulation caused by dust, and fully automated equipment operation for key processes;
2. Full range vehicle specification reliability verification**
100% factory inspection includes AOI optical testing, impedance testing, bending fatigue testing, high and low temperature cycling, wet heat aging, high voltage withstand testing, salt spray testing, and vibration impact verification. A complete inspection report is issued for each batch;
3. Flexible delivery mode**
Research and development samples can be quickly sampled within 5-7 days, with small batch trial production and stable supply for large batch long-term orders. We can provide one-stop services for backend SMT surface mount PCBA;
4. Complete vehicle company reporting materials**
We can provide material certification, RoHS, REACH, IATF16949 certificates, reliability testing reports, FMEA analysis documents, and directly assist customers in completing the application for entry of components into the vehicle.
7、 Brand Conclusion
Zhejiang Kunying Flexible Soft Plate Factory of China Chaosheng Group builds every on-board soft and hard FPC with strict vehicle specification manufacturing standards, uses highly reliable circuits to protect the three electricity safety of new energy vehicles and the stable operation of auto drive system, helps the domestic automotive electronics industry chain to be self controllable, and supports the one-to-one in-depth customized development of customer drawings and specifications.
Supporting: Full range of FPC in car English keywords
1. Single layer automotive flexible FPC: Single layer automotive flexible FPC
2. Double Layer Automotive FPC: Double Layer Automotive FPC
3. Multi layer Automotive Flexible PCB: Multi layer Automotive Flexible PCB
4. Roll to Roll Automotive FPC/R2R Auto Flex Circuit
5. Automotive Rigid Flex PCB/Vehicle Grade Rigid Flex FPC
6. Extra Large Size Automotive Flexible PCB: Extra Large Size Automotive Flexible PCB
Long tail tags * *: IATF16949 rigid flex PCB, EV BMS FPC, ADAS camera rigid-flex board, New Energy Vehicle flexible circuit, AEC-Q200 automotive flex PCB
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