Applications and Types of PCBs For Automotive Industry

RAYMING PCB & ASSEMBLY
Applications and Types of PCBs for Automotive Industry
Introduction
Printed circuit boards (PCB) play a pivotal role in the functioning and
performance of automotive electronics. From powertrain systems to ADAS,
infotainment and lighting, PCBs can be found enabling various functions.
The harsh under-the-hood environment along with increasing electronics
complexity impose stringent requirements on automotive PCBs. In this
article, we will take a look at key PCB applications in vehicles, critical
design considerations and specialized PCB types used in the automotive
industry.
PCB Applications in Automotive
Some major application areas using PCB technology in modern vehicles:
Powertrain Control
 Engine control unit
 Transmission control module
 Battery management system
 Traction inverter & converter
ADAS Systems
 Camera modules
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 Radar PCBs
 LiDAR electronics
 Vision processing units
Infotainment Head-units
 Navigation system
 Audio amplifier
 Telematics gateway
 Display graphics module
Body Control
 Lighting/luminaire PCBs
 Door control module
 HVAC control
 Central gateway ECU
Instrument Clusters
 Odometer
 Driver information display
 Telltales and warning lights
Security Modules
 Immobilizer PCB
 Central locking ECU
 Blind spot detection
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PCB Design Challenges in Automotive
Automoti
ve Electronics
Designing PCBs for automotive applications brings unique challenges:
High Vibration/Shock Loads
 Vibration from engine and road noises.
 Shock from bumps and unequal road surfaces.
Wide Temperature Range
 Under-the-hood temperature up to 125°C.
 Cold temperature down to -40°C.
Electromagnetic Interference

 Switching noise from motors and actuators.
 RF interference from transmitters.
High Voltages
 DC bus voltage upto 650V in electric vehicles.
 Fast transients like load dump.
Mixed Signal Circuits
 Combination of sensitive analog and noisy digital circuits.
Safety and Reliability Critical
 Rigorous product validation needed.
 Adherence to ISO26262 functional safety standard.
Key PCB Design Considerations
To meet the demanding automotive environment, certain design practices
are followed:
Component Selection
 Automotive grade components rated for extended temperature
range.
 Parts qualified based on AEC-Q101 standard testing.

Layout Design
 Minimum clearance and creepage distance as per ISO 6469-3.
 Safety critical layout separation and partitioning.
Power Integrity
 Robust power distribution network design.
 Protection against voltage transients.
 Effective grounding.
Signal Integrity
 Controlled impedance routing for high-speed buses.
 Effective EMI and noise filtering.
Thermal Management
 Suitable dielectric materials like polyimide for higher temperature
rating.
 Thermal vias/slots for heat dissipation.
Vibration Resistance
 Component bonding, underfill and encapsulation techniques.
 Board stiffening elements like aluminum baseplate.
Conformal Coating

 Paraxylene, acrylic, polyurethane or epoxy coating.
 Protection against dust, moisture, chemicals.
Safety Standards
 Compliance to ISO 26262 Functional Safety standard.
 Adherence to MISRA coding guidelines.
Reliability Testing
 Industry standard validation as per AEC-Q100, AEC-Q101.
 Accelerated testing – temperature cycling, humidity, HASS etc.
Types of PCBs Used in Automotive
RF
Board for for automotive collision avoidance radar

Different types of PCB technologies and constructions are leveraged to
meet the demanding automotive application requirements:
Rigid PCBs
 Conventional FR-4 glass epoxy rigid PCBs.
 Higher Tg variants like FR-4 High Temp for thermal reliability.
 Halogen-free and flame retardant materials.
 Metal core boards for thermal management.
Flexible PCBs
 Single, double or multilayer flex circuits.
 Suit applications with space constraints or movement.
 Polyimide material for flexibility at higher temperatures.
Rigid-Flex PCBs
 Combination of rigid and flexible sections.
 Allows three dimensional routing.
 Used to interconnect multiple PCBs.
Metal Backed PCBs
 Insulated metal substrate (IMS) or metal core PCBs.
 Metal baseplate aids heat dissipation and EMI shielding.

High Frequency PCBs
 RF designs with precise impedance control and absorbers.
 Low-loss material substrates like PTFE.
 Synthetic heat sinks for power amplifiers.
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New PCB Trends in Automotive
Emerging trends in automotive PCB technologies include:
HDI PCBs
 High density interconnects to integrate more functionality.
 More routing layers, microvias and thinner dielectrics.
High Thermal Conductivity Dielectrics
 Dielectrics with ceramic fillers for improved thermal dissipation.
Low Temperature Co-fired Ceramic (LTCC)
 Multilayer ceramic PCBs for demanding RF and power modules.
Additive Processes
 Additive fabrication to produce high aspect ratio fine features.
 Technologies like aerosol jet printing.

Embedded Passives
 Passives like resistors and capacitors integrated within the PCB.
 Saves space and improves electrical performance.
Panel Level Packaging
 Panel scale manufacturing vs single PCBs.
 Allows integration of PCB, ICs, passives etc.
Quality and Reliability Testing
 Higher reliance on automotive industry standards like
AEC-Q100/101, IPC-A-610G Automotive Addendum.
 In-circuit and functional testing.
 Accelerated life testing.
Conclusion

From engine control units to ADAS cameras, PCBs have become
indispensable in modern vehicles due to the electronics revolution.
Automotive PCB design requires mastering signal integrity, robust power
distribution, thermal management and mechanical reliability while
meeting stringent industry standards. As automotive electronics
complexity grows exponentially, innovations in PCB materials, high density
integration, quality/reliability validation and panel scale manufacturing will
be critical to realize future mobility visions.
FAQs
1. What are some key factors driving increased electronics content in
automobiles?
Demand for connectivity, infotainment, electrification, autonomous
features is driving rapid growth in automotive electronics content.

1. What is the typical temperature rating required for under-the-hood
automotive PCBs?
Due to high temperature environment, under-the-hood PCBs must
withstand temperatures of 105°C to 125°C.
1. How does ISO26262 relate to automotive PCB design?
It provides an automotive functional safety framework with requirements
traceability impacting PCB design validation.
1. Which construction provides higher thermal conductivity – IMS or
MC PCB?
Insulated metal substrate (IMS) has dielectric directly bonded to metal
baseplate giving higher thermal conductivity than metal core PCB.
1. What are some key board level reliability tests done for automotive
PCB qualification?
Common reliability tests include temperature cycling, shock/vibration,
humidity/bias, HTOL (high temperature operating life) etc.
The industrial sector has seen a tremendous boom in past decade when
the demand in automobile exponentially increased due to rapidly growing
automation technology. Today the automobile giants like Toyota, Honda,
BMW, Ford and Tesla are producing such a high class automobiles and
targeting specific consumer class that can buy such a marvelous piece of
art of automation engineering. Besides mechanical engineering miracles
we all know that brought the revolution in cars and automobile vehicles,
the electronics engineering industry has now got involved extensively in
automobile industry. Today’s automobile vehicle is a combination of true
art of mechanical and electronics engineering. All of the aesthetics that we
see in high class sports car like Lamborghini or Ferrari, or we see power
control system in heavy loaded trucks like Caterpillar or Komatsu lifters,
cranes etc we see that the control system working behind is based on
some sort of Electronic Control System (ECS). And this ECS is founded on
Special kind of Automotive PCB.
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Applications of Automobile PCBs:
Like Caterpillar 797F mining truck has the electronic clutch pressure
control, service break sensor, Engine sensor, ARC switch, service break,
secondary break control, axle speed sensor circuit, position and steering
sensor circuits. There are lots of other examples of general use consumer

cars with impressive dashboard, with LED or LCD display, GPS and radar
electronics embedded on dashboard, FM radio, automatic doors and
locking systems, electronic relays to control fuel valves/solenoids, timer
circuits for engine, Engine Control Unit (ECU) or Engine Control System
(ECS) PCB modules, automatic mirror controller, Airbag controller, and
front, rear and side LED light control and drive circuits for headlights, back
lights and indicator lights respectively, car speed and acceleration sensor
and display circuits, Car Battery Management system circuits, wireless key
remote door locking system for car safety, air conditioning control etc.
The auto driver system in modern automobile cars is totally PCB based
and highly sophisticated electronic circuits are functioning behind the
scene. These PCBs are made pre-programmed for sensing the
surrounding environment of car to detect obstacle around it in neat
vicinity. This is commonly done by IR and Doppler radar system. The
auto robot car driving system will take control of car brake, clutch and
race and makes decision based on the inputs from surrounding
and programming fed in the complicated automotive PCBs.
Although these automobile PCBs are powered by car batteries which is in
most cases maintenance free batteries and all the car electronics is
operated by this 12VDC battery system. The cabling and wire harness is

laid inside the car along with fuses to prevent the electronics from over
current or overvoltage surges.
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Electric Vehicle:
Nowadays, we see in newspaper, electronic media and people talking
about future cars that will run totally on batteries and no fuel or diesel will
be required for car now. Yes this is true, scientist and engineers have
come-up with a new invention in the battery system that these batteries
will charge in the matter of few hours and will give backup to your care for
many days. This system is just like our smart-phones that once charged in
few hours will give back-up 2-3 days. But there are differences in this novel
technology because some electric vehicle will give few days of back and
mileage while other can gives battery charging power for weeks. Obviously,

the technology of E-Vehicles or Electric Vehicle is not possible without
Automotive PCBs. Although our discussion in previous section was just to
power up the accessory car electronics and engine control while the fuel
was still the diesel and oil, while here in this case the car is totally
“electrified” completely eliminating the need of fuel or diesel.
Types of Automotive PCBs:
From our discussion above it is clear that the automotive PCBs should be
something that will give the highest performance in terms of power
dissipation, efficient heat transfer, long life cycle and robustness.
Commonly if we open up the deck or dashboard of our cars we see a
complex electronics and wiring inside with relays, fuses and sockets
mounted and connecting various modules with each other.
These Electronic components are all mounted on Rigid PCBs that are High
Density Interconnect (HDI) PCBs, Heavy copper PCBs to allow high amount

of current flow from car battery to accessory electronic, ceramic substrate
PCBs to bear against harsh, stringent environment of car surrounding like
car moving in deserts, forest, mountainous regions or running in hot
sunny weather.
The aluminum based Metal Core PCBs (MCPCBs) are commonly seen in
automotive electronics that consist of bright LED lights. These bright LED
lights draw high current from battery and in turn gives high luminosity
white light. Moreover the small motors hidden inside car body to control
the cars fins, windows, side mirrors or any part that is moving, draws good
enough current from battery. Hence the need of heavy copper PCB is
required to provide least resistance path to the flow of current so as to
protect/avoid PCB to melt down due to high temperature / heat generated
by high currents.
There are flexible PCBs also found in car electronics front dashboard,
connecting large LED, LCD display to the processor board, or connecting
various electronic modules each other by flexible PCBs. Flexible PCBs are
light weight and can be adjusted/flexed inside the small space available in
car deck/dashboard. The combination of rigid and flexible PCBs
called Rigid-Flex PCBs are also found in Automotive PCBs.

Rayming PCB Services for Automotive PCBs:
At Rayming PCB Our expertise in manufacturing automotive PCBs is vast.
We assure high quality and robust PCB manufacturing services. Our PCBs
are ISO 9001-2008 and UL certified, so you know they are reliable, durable
that will last long. We are the one-stop shop for all your PCB
manufacturing and assembly needs. Our proven reputation among our
valued clients shows the quality product we deliver. Please send us the
design specifications and details about your Automotive PCB at this email
sales@raypcb.com
Future of Automotive and PCB Industry Together:
These two gigantic industries can change the shape of the automation
industry. As we witness today that cars have been invented totally

depending upon electricity and batteries and completely knocking out the
need of fuel pumps. Now in future electric charging stations will charge
your car like a smart-phone and your will then drive your car more “Energy
efficiently” and more environment friendly. Having said that, the
electronics PCB manufacturing and assembly industry is the Part and
Parcel of automotive industry. It is just the matter of time that world
would see these automotive PCBs being used as an integral part of every
car’s engine electronics, as car’s accessories electronics and completely
replacing mechanical fuel engines with electronic car engines and
interface electric motors to drive your car effectively.
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3. Properties, Benefits and Applications of Ventec Vt47 for PCB
Industry
4. What are the Types and Applications of the Digikey PCB?
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RAYMING PCB & ASSEMBLY

Applications and Types of PCBs for Automotive Industry

performance of automotive electronics. From powertrain systems to ADAS,

infotainment and lighting, PCBs can be found enabling various functions.

The harsh under-the-hood environment along with increasing electronics

complexity impose stringent requirements on automotive PCBs. In this

article, we will take a look at key PCB applications in vehicles, critical

design considerations and specialized PCB types used in the automotive

PCB Applications in Automotive

Some major application areas using PCB technology in modern vehicles:

 Engine control unit

 Transmission control module

 Battery management system

 Traction inverter & converter

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 Vision processing units

 Display graphics module

 Door control module

 Central gateway ECU

 Driver information display

 Telltales and warning lights

 Central locking ECU

 Blind spot detection

Request PCB Manufacturing & Assembly Quote

PCB Design Challenges in Automotive

Designing PCBs for automotive applications brings unique challenges:

High Vibration/Shock Loads

 Vibration from engine and road noises.

 Shock from bumps and unequal road surfaces.

Wide Temperature Range

 Under-the-hood temperature up to 125°C.

 Cold temperature down to -40°C.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 Switching noise from motors and actuators.

 RF interference from transmitters.

 DC bus voltage upto 650V in electric vehicles.

 Fast transients like load dump.

Mixed Signal Circuits

 Combination of sensitive analog and noisy digital circuits.

Safety and Reliability Critical

 Rigorous product validation needed.

 Adherence to ISO26262 functional safety standard.

Key PCB Design Considerations

To meet the demanding automotive environment, certain design practices

 Automotive grade components rated for extended temperature

 Parts qualified based on AEC-Q101 standard testing.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 Minimum clearance and creepage distance as per ISO 6469-3.

 Safety critical layout separation and partitioning.

 Robust power distribution network design.

 Protection against voltage transients.

 Controlled impedance routing for high-speed buses.

 Effective EMI and noise filtering.

 Suitable dielectric materials like polyimide for higher temperature

 Thermal vias/slots for heat dissipation.

 Component bonding, underfill and encapsulation techniques.

 Board stiffening elements like aluminum baseplate.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 Paraxylene, acrylic, polyurethane or epoxy coating.

 Protection against dust, moisture, chemicals.

 Compliance to ISO 26262 Functional Safety standard.

 Adherence to MISRA coding guidelines.

 Industry standard validation as per AEC-Q100, AEC-Q101.