Improved Harness Technology™

Amphenol Trackwise specialises in producing multilayer flexible printed circuits (FPC) of any length thanks to their patented* manufacturing process known as Improved Harness TechnologyTM (IHT),   This innovative technology is exclusively available at their facility in Stonehouse, Gloucestershire, UK.

 Products made using IHT offer significant weight and space savings, increased repeatability and reliability, and reduced assembly time.

These interconnects are flexible in more than just name. They can be:

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

World’s largest multilayer flexible PCBs

In weight and size sensitive applications, flexible PCBs such as those produced by Amphenol Trackwise can provide significant advantages.  When used as a replacement to traditional wiring harnesses, IHT offers an interconnect solution with significant benefits in terms of reliability, repeatability and more importantly, in the reduction of space required and weight – up to 75% saving. 

This 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 (FPCBs) were initially developed as a lightweight, space-saving alternative to traditional wire harnesses. Since the 1960s, they have grown into a multi-billion-dollar global industry.  Their adoption has been limited due to the length of product available, typically 610mm, however, with the advent of IHT, this is no longer the case.

As a result of a patented process innovation, Trackwise is now able to offer length-unlimited multilayer flexible printed circuit boards – a globally unique capability. To the best of our knowledge, Amphenol Trackwise has manufactured the world’s largest flexible multilayer PCB of 234ft for an industrial application in the UK.

Several steps in the manufacturing process of PCBs are traditionally static in nature and equipment used in these static processes defines the capability – Drilling, Imaging, Pressing, Plating.  However, Amphenol Trackwise’ innovation transforms these static processes into dynamic ones through the modification of existing PCB and roll-to-roll electrolaminate equipment and manufacturing techniques.

As a result, instead of being constrained by supply chain limitations, the only restriction is determined by the application’s specific requirements.

  • Smaller
    Flexible printed circuits employ ultra-thin dielectric substrates, making them ideal for compact electronic interconnections. In some cases, these circuits can be manufactured with a total thickness of less than 50μm (0.002″), including a protective cover layer.

    This size reduction, combined with their flatness, or planary, allows flexible circuits to be bonded to or even integrated within the structures they are mounted on. As a result, they occupy minimal physical volume, optimising space efficiency in advanced applications.
  • Lighter
    The use of flexible PCBs to replace traditional wire harnesses offers significant weight reduction, a key advantage for industries where reduction in mass is important, such as aerospace and alternatively fueled vehicles.

    Unlike conventional wire harnesses, which often require a minimum standard wire gauge that is selected for mechanical strength rather than electrical needs, flex PCBs contain an integral composite structure that provides mechanical durability  This removed the need for oversized conductors to provide strength allowing the copper cross-section to be tailed to what is required in order to carry the current load or to satisfy voltage drop requirements..
  • Efficient
    Unlike wire harnesses, which are prone to human error during hand assembly, FPCs eliminate this risk. They reduce the number of assembly steps required by enabling the users to fully design, build, and test circuits before assembly. Their design-driven nature also ensures that all routing and connection are digitally created and controlled, leaving no room for manual mistakes. While the design may be in error, a flexible circuit cannot induce errors of human nature

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

Some manufacturers can make circuits up to 30 metres (100 feet) but these are single and double-sided circuits only. Others can make multilayer circuits up to 5 metres (16 feet) but Trackwise length-unlimited offering is unique. Trackwise makes 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
    Aluminium 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.

Patents

  • 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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