Improved Harness Technology™

Improved Harness Technology TM (IHT) is the proprietary patented manufacturing process that allows the manufacture of multi-layer, flexible printed circuits of any length. Our IHT products offer significant weight and space savings, increased repeatability and reliability, and reduced assembly time.

They can be multi layered or single layered; point-to-point interconnects or carry SMDs to become APCBs, withstand harsh environments ( from -110c to 260c, 40gRMS vibration), or be fine enough to replace microwires in medical catheters and endoscopes (less than 100um track and gap).

World’s largest multi-layer flexible PCBs

A patented process innovation* has extended Trackwise’ capability to the manufacture of flexible multilayer printed circuit boards of any length, making these the world’s largest flexible multilayer PCBs.

In high value, mass-critical applications, boards of such length can be used as an alternative to traditional wiring harnesses, offering significant benefits in terms of reliability, repeatability and moreover in the reduction of space required and weight – up to 75% saving.

*European Patent No. 2810543, UK Patent No: GB2498994, US Patent No: US2015108084, Canada Patent No: 2862772, Brazil Patent No: BR1120140190330, China Patent No: ZL201380011859.6

Flexible printed circuit boards were developed as a replacement for wire harnesses in order to save weight and space.  Since the 1960s, they have become a multi-billion dollar global industry.

The application of flexible PCBs has however been limited due to the length of product available.  Due to manufacturers’ limits (typically 610mm), product application has in general been limited to inside a box or equipment – rather than between boxes.  Until now.

As a result of a patented process innovation, Trackwise is now able to offer length-unlimited multi-layer flexible printed circuit boards – a globally unique capability.

A few PCB manufacturing process steps are static in nature and equipment used in these static processes defines the capability – Drilling, Imaging, Pressing, Plating.

Trackwise’ innovation changes these static processes and makes them dynamic; innovative modification of existing PCB and roll-to-roll electrolaminate equipment and manufacturing techniques.

The outcome of this is that, rather than the supply chain defining the limits the only limit is that of the application itself.

In the years since traditional wire harnesses have been able to be replaced by flexible printed circuits, the multi-billion dollar nature and global adoption of this technology is clear evidence of the widespread benefits of employing flex circuits. This global industry is supported by globally accepted standards, specifications and design guidelines, a mature material supply chain and a widespread talent pool of designers and fabricators.

The benefits of using flex PCBs in place of conventional wire harnesses are well documented from unit level to subsystem or even system level.  Improved Harness Technology™ simply expands the field of application of those benefits.

These include:

  • Reduction in interconnect size
    Flexible circuits employ the thinnest dielectric substrates available today for making electronic interconnections. In some cases, it is possible to produce flexible circuits having a total thickness less than 50μm (0.002″), including a protective cover layer.

    This reduction in size, coupled with their planarity, makes them suitable for bonding to, or even within, the structure to which they are mounted. This further reduces the physical volume occupied by the interconnect.
  • Reduction in interconnect weight
    The weight reduction possibilities of using flex PCBs to replace conventional wire harnesses can be a major attractor for many industries, including aerospace.

    A corresponding benefit of reduction in interconnect size is reduction in interconnect weight. Thinness equals reduced weight.

    Conventional wire harnesses will use a minimum wire gauge that is selected for mechanical (strength) reasons, rather than sized by what is required electrically. As a flex PCB is an integral composite structure, the integral construction provides the mechanical strength and so it is not necessary to select large conductors for strength. The copper cross-section can thus be reduced to what is required in order to carry the current load or to satisfy voltage drop requirements.
  • Reduction in interconnect assembly time – as well as risk and cost
    The main reduction benefit is derived both from the ability to reduce the number of assembly operations required and from the user’s ability to build and test the circuit completely prior to committing the circuit to assembly. This especially applies to wire harness replacement applications.

    While the design may be in error, a flexible circuit cannot induce errors of a human nature. Human error in hand-assembly is a constant risk. An area especially vulnerable is in the assembly of hand-built wire harnesses. With flexible circuits, all design features are controlled by the design itself. As a result, with the exception of process-induced errors in manufacturing, it is not possible to route circuits to points other than those designated by the circuit design.

For more information regarding replacing shielded twisted pairs with flex, please visit our White Papers page to download the PDF.

Trackwise’ ability to manufacture length-unlimited multilayer flex PCBs is unique.

There are manufacturers can make circuits up to 30metres (100foot) but these are single and double sided circuits only. Others can make multilayer circuits up to 5metre (16foot) but Trackwise length-unlimited offering is unique. Trackwise make length-unlimited multilayer flex circuits.

A printed circuit board is the implementation of customer requirements – so contact us with your requirements and we will try to help

  • Flex
    Max length Unlimited, max. width 600mm
  • Flex/rigid
    Max length 2200mm, max. width 600mm
  • Materials
    PI/PTFE/PEEK/FR4 (semi-flex)
    Not all materials are available in roll-form so please ask.
  • Conductor materials
    Copper up to 2oz
    Aluminum for lightweight GND

Trackwise is constantly investing in its in-house capability and capacity to manufacture long flex.   Our 77,000 sq.ft manufacturing facility in Stonehouse, Gloucestershire was commissioned in 2021, and there will be more developments over the coming years.

As a result of work carried out under a European Clean Sky research project, LHTFPCB, Trackwise (UK) and Rogers (Belgium) are pleased to be able to offer large format (up to many metres in length) flex PCBs, demonstrated to be capable of operating at temperatures up to 260C for long durations, even in high vibration environments, 40gRMS.

As aero engines are designed to run hotter as part of a drive to increase efficiency, such high temperature circuitry offers the designer the ability to increase control of the engine.

The flex PCBs have been manufactured using Rogers’ PEEK based circuit materials – also highly chemically inert and with high radiation resistance.

Additional work is being carried out on extending the temperature range and/or longer life at 260C by means of additional oxidation barriers.

Test equipment (thermal cycling and RV ovens) has been developed capable of proving high temperature flex PCB performance at temperatures up to 400C. These are available at Trackwise for use in other applications.

The LHTFPCB project has completed, with TRL 6.

Clean Sky is the most ambitious aeronautical research programme ever launched in Europe. Its mission is to develop breakthrough technologies to significantly increase the environmental performances of airplanes and air transport, resulting in less noisy and more fuel efficient aircraft, hence bringing a key contribution in achieving the Single European Sky environmental objectives.
For more information please visit LHTFPCB.

Patented process innovation – allows for the manufacture of flexible multilayer printed circuits of any length

  • UK Patent Number GB2498994 – granted March 2014
  • US Patent Number US2015108084 – granted January 2016
  • China Patent Number ZL201380011859.6 – granted April 2018
  • EU Patent Number 2810543 – granted August 2019
  • Canada Patent Number 2862772 – granted July 2020
  • Brazil Patent Number BR1120140190330 – granted December 2021

WHITE PAPERS

For more information regarding replacing shielded twisted pairs with flex, please visit our White Papers page to download the PDF.

Read more

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