Single Flex Substrate Rigid-Flex PCB

A hybrid circuit board constructed with a single continuous flexible polyimide substrate as the core interconnection medium, selectively laminated with rigid boards in specific zones. Key characteristics:
1. Base Structure: Entire circuitry built on one monolithic flex layer (typical thickness: 25-100μm);
2. Selective Rigidization: Rigid laminates (e.g., FR-4) bonded only where mechanical support/components are needed;
3. Unified Routing: Copper traces run continuously across flex and rigid zones without electrical disconnection.
Core concept: "Flex-centric, rigid-augmented" topology (vs. traditional rigid-dominant designs).

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Product Characteristics

1. Flex-Dominated Architecture
Entire circuitry fabricated on a single polyimide flex core (25-100μm), with rigid laminates selectively bonded only to critical areas.

2. Ultra-Thin & Lightweight
Total thickness ≤0.4mm (vs. ≥0.8mm for traditional rigid-flex), weight reduction >50%, bending stiffness as low as 0.05N/mm².

3. Enhanced Dynamic Flexibility
Flex zones occupy >70% area, enabling multi-directional bending (min. radius ≥3x thickness) with >500k flex cycles (IPC-6013D Class 2).

4. Localized Rigidization
Rigid zones cover only component/connector footprints (<30% area), serving solely as mechanical anchors without electrical function.

5. Seamless Routing Continuity
Traces patterned continuously across rigid-flex boundaries on the monolithic flex layer, eliminating impedance discontinuity (insertion loss <0.1dB@1GHz).

6. Manufacturing Efficiency
40% fewer lamination cycles vs. traditional rigid-flex, yield rate >90% due to simplified stack-up.

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Product Application Field

Ultra-Thin Wearables

Smart Bands/Watches: 0.3mm flex conforming to wrist curves, rigid zones only for charging pads/sensor ICs.
Medical Patches: ECG electrodes on flex, micro rigid zones (＜5mm²) for Bluetooth modules.

Endoscopic & Surgical Tools

Endoscope Articulating Arms: Monolithic flex through multi-joints (Ø≤2mm), rigid zones at lens/LED modules (autoclavable).
Surgical Robot Wiring: 360° torsion capability, rigid ends for connectors (ISO 13485 compliant).

Foldable Display Hinges

Phone/Tablet Flex Circuits: Dynamic routing between screen and mainboard, rigid zones anchored to assemblies (＞200k bend cycles).

Micro-Drones & Robotics

Gimbal Motor Wiring: Flex wrapped around shafts, rigid zones for gyro ICs (50% lighter than cables).
Robotic Finger Joints: Multi-segment flex mimicking tendons, rigid zones for force sensors.

Automotive Electronics

Seat Pressure Sensing Arrays: Flex embedded in cushions, rigid nodes for signal processing (thickness≤0.4mm, load＞100kg).
In-Cabin Camera Modules: Flex linking lens to PCB, vibration-resistant (AEC-Q100 certified).

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