Elementary, Mr. Watson: Slash Sheets a ‘Smorgasbord’ of Materials

Slash sheets touch on materials, one of my favorite areas of PCB design, and what I refer to as “the buffet of the PCB world.” After all, this smorgasbord of materials comes in an endless variety, with differing balances of reinforcement and resin, from different manufacturers and vendors, and from a variety of sources. Add the possibility of out-of-date or deteriorated panels, and it makes ensuring the quality of your next PCB design a real hit or miss. Think of it like looking at a variety of available restaurants. To determine whether they are “safe and clean,” and meet quality standards, the health department conducts regular inspections, and gives them ratings which help us know whether it meets our standards.

It seems that nothing has more impact on a successful PCB than its materials. In general, a working PCB comprises some essential, everyday items like fiberglass, resin, and copper. Add the physics to the mix, and you have a working PCB. The materials determine the electrical and thermal properties of every PCB. Certain types of materials are not a choice but a must, especially for high-speed or power PCBs. Choosing the wrong material can affect signal integrity (SI) and lead to potential disaster, including premature system failures and added costs to a company. Often these issues do not show up until long after the PCB has left a company.

Slash Sheets, Defined
Slash sheets provide information on specific materials used in manufacturing PCBs, including the material's properties, specifications, and usage instructions. It is essential to use the correct material in the manufacturing process to ensure that the final product meets required standards.

Basically, slash sheets answer this simple question: Does a specific material meet the requirements or standards of IPC-4101 and IPC-4103?

History and Evolution of Slash Sheets
Slash sheets were introduced in the 1980s to standardize all the different materials used in the PCB industry. The original slash sheets were simple documents that provided basic information on materials. However, as technology and manufacturing processes evolved, so did the need for more detailed information on materials.

According to IPC-4101, each slash sheet has a set of criteria to help determine whether a specific material matches the requirements. The standard has four categories which provide comprehensive requirements for the performance and properties of laminate and prepreg materials used in manufacturing PCBs. The standard also defines several vital areas used to validate a specific PCB material.

Mechanical properties: This covers the material's mechanical strength, dimensional stability, and thermal expansion. They are important because they affect the reliability and performance of the PCB, particularly in high-stress or high-temperature applications.

Electrical properties: This covers the electrical insulation, dielectric constant, and loss tangent of the material. They are important because they affect the signal integrity and reliability of the PCB, particularly in high-speed digital or high-frequency applications.

Thermal properties: This covers the material's thermal conductivity, thermal resistance, and glass transition temperature. They are important because they affect the heat dissipation and thermal management of the PCB, particularly in high-power applications.

Chemical properties: This covers the material's chemical resistance, moisture absorption, and flame retardance. They are important because they affect the durability and safety of the PCB, particularly in harsh or hazardous environments.

These areas are then broken down further into reinforcement type (usually fiberglass) and resin material system (usually an epoxy mix).

Table 1: Break down of reinforcement type

Watson_May_fig1 (1).jpg

PCB Reinforcement Types

Woven E-glass Core

The most popular PCB reinforcement is woven E-glass, although, according to IPC-4101, expected reinforcements are nonwoven E-glass core, unidirectional E-glass, and nonwoven aramid paper. The go-to reinforcement is FR-4, or fiberglass PCB, which uses a woven fiberglass material as its core substrate. The fiberglass material comprises thin strands of glass that are woven into a mat, which is then coated with epoxy resin to create a rigid and durable material.

The use of woven E-glass provides excellent mechanical strength and dimensional stability to the PCB, making it suitable for applications that require high reliability and durability. Woven E-glass PCBs also have good electrical insulation properties, which make them ideal for high-speed digital and analog circuits.

Cellulose Paper Core

Cellulose paper core are PCBs that use a core material made of cellulose paper impregnated with phenolic resin. In the PCB industry, this core material is often called FR-2 or phenolic paper.

The cellulose paper core provides good mechanical strength and dimensional stability to the PCB, while the phenolic resin provides excellent electrical insulation properties. That makes cellulose paper core PCBs ideal for low-cost, low-power applications where high-frequency performance is not critical.

Resin Material Systems

The IPC-4101 standard defines several resin material systems, each with its own properties and characteristics. These include:

  • Epoxy resin systems are the most used in the PCB industry due to their excellent mechanical properties, chemical resistance, and electrical insulation properties.
  • Polyimide resin systems are used in high-temperature applications due to their exceptional thermal and dimensional stability.
  • Cyanate ester resin systems are used in applications that require high stiffness and low dielectric constants, such as microwave and high-speed digital circuits.
  • BT (bismaleimide triazine) resin systems are used in applications that require high thermal stability and low dielectric constant, such as high-speed digital and RF circuits.
  • PTFE (polytetrafluoroethylene) resin systems are used in applications that require exceptional electrical insulation properties and low-loss tangents, such as microwave and RF circuits.

Each resin material system has its properties and characteristics and is tested and validated against specific requirements defined in the IPC-4101 standard. By selecting the appropriate resin material system for a particular application, PCB designers can ensure that their boards have the necessary mechanical and electrical properties to meet the application's requirements.

Tg or Glass Transition Temperature
Tg is when a material transitions from a rigid, glassy state to a softer, rubbery state. It is the temperature at which the polymer chains within the material begin to move more freely, allowing the material to become more flexible and elastic. The Tg of the material used in the PCB determines the maximum temperature at which the board can operate without experiencing mechanical or electrical failure due to thermal stress.

Dk (dielectric constant), on the other hand, refers to the ability of a material to store electrical energy in an electric field. It measures how much a material's capacitance changes relative to air (or a vacuum), which has a Dk of 1 MHz. Both are related to the thermal properties of the material.

A significant problem I've experienced with material manufacturers (especially those who are, let's say, less honest) is their claim that a particular material matches the requirement of an IPC-4101 slash sheet. It is difficult to verify the chemical breakdown of a material after the fact. It usually requires Fourier transform infrared (FTIR) spectroscopy, ion chromatography (IC), and differential scanning calorimetry (DSC) at, of course, significant cost.

John Watson, CID, is a customer success manager at Altium.

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2023

Elementary, Mr. Watson: Slash Sheets a ‘Smorgasbord’ of Materials

05-15-2023

Slash sheets touch on materials, one of my favorite areas of PCB design, and what I refer to as “the buffet of the PCB world.” After all, this smorgasbord of materials comes in an endless variety, with differing balances of reinforcement and resin, from different manufacturers and vendors, and from a variety of sources. Add the possibility of out-of-date or deteriorated panels, and it makes ensuring the quality of your next PCB design a real hit or miss.

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Elementary, Mr. Watson: Responsible PCB Design Must Go Beyond RoHS

04-21-2023

In the field of PCB design, a massive paradox exists. No doubt, the PCB industry is a fascinating field. The ever-changing design environment faces constant and more complex challenges to make products smaller, faster, and cheaper. There are endless ways that electronic innovation changes lives for the better, as seen when advanced medical systems provide patients a new lease on life. But there also is a downside, an unfortunate side, to PCB design, and it has bothered me for some time. There is a massive amount of new PCB products hitting the market, especially in the consumer marketplace. But what happens to the "obsolete" products that are discarded, known as e-waste? This dark side of the PCB industry is not spoken about in social circles, but with innovation comes some negative.

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Elementary, Mr. Watson: If Not You, Then Who?

03-23-2023

I have had the opportunity to do a considerable amount of traveling. Over many visits to the Philippines, I noticed a distinct lack of nursing homes, and learned that it is a common practice for children to take care of their parents. They even have a designated term for this practice, ma alaga, roughly translated as "take care of." This practice leads to some fantastic outcomes in the culture, resulting in each age group taking care of its own, with a beautiful overlapping of different generations. What a great concept.

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Elementary, Mr. Watson: Turning Your Career up to Eleven

02-16-2023

In the 1984 classic rock documentary “This Is Spinal Tap,” guitarist Nigel Tufnel proudly demonstrates an amplifier whose volume knobs are marked from zero to 11 instead of the typical zero to 10. From that movie, we get the phrase, “Turn it up to 11.” It’s a lesson of seeing a limit and exceeding it. So, here’s a rather personal question: What is your level 11? You are the only person who can answer that question, and I hope you will, both in your personal life and in your career.

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Elementary, Mr. Watson: Advanced Packaging Not a Passing Fad

01-30-2023

As it is said, necessity is the mother of invention. That is precisely the situation when we are discussing the PCB design industry. We are living in what can only be described as the golden age of Electronics. The advancements and innovations are growing by leaps and bounds. Never in history has the field of electronics grown at such a fantastic rate. The advance integration packages field is one of the fastest-growing and most exciting.

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Elementary, Mr. Watson: Designing For a Higher Purpose

01-12-2023

John Watson asks the question to PCB designers: Why do you do what you do? It's a question someone asked him recently and the answer was clear. In this column, John shares a personal journey of a friend whose life was changed in an instant because of the efforts of so many, including a PCB designer. This story should give us all pause to consider the magnitude of what we do. The "puzzle pieces" of a PCB design become a working model for consumer products that affect even our most basic senses. Read on to learn more about the "why" behind his passion for PCB design.

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2022

Elementary, Mr. Watson: The Art of the PCB

12-15-2022

After finishing the statue of David, Michelangelo—Italian sculptor, painter, architect, and poet of the High Renaissance—was asked how he had created such a beautiful work of art. He said, “The sculpture was already complete within the marble block before I started my work. I merely had to chisel away the superfluous material.” After decades of being in the industry and seeing countless designs, it’s still amazing to me to see the exceptional beauty of a well-done PCB design. For designers, each PCB begins as a blank canvas; not knowing what the final product will look like, we walk a fine line between engineering and artistry, often producing fascinating results.

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Elementary, Mr. Watson: Is Your Bathroom in the Kitchen?

11-10-2022

Several years ago, a report came out of St. Louis of a strange apartment on the market. It was in the community of Central West End. With a small floor plan of only 200 square feet, the entire bathroom was placed right in the middle of the kitchen. Well, that's interesting. It gives new meaning to the studio apartment. Well, with closer examination, there are several convenient features available, so here's my point: In this story lies some fantastic lessons for us as PCB designers. In real estate, it's pretty uncommon to find the bathroom in the kitchen; but metaphorically speaking, it's done all the time in a PCB design (ouch).

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Elementary, Mr. Watson: Is the Tail Wagging the Dog?

10-13-2022

I recently had the opportunity to work on a rather critical PCB design project during what should have been the final design review. Unfortunately, after presenting my well-organized PowerPoint presentation, I asked the most challenging question to the group of assembled engineers and managers, “So, what do you think?” As we went around the room, nearly every comment started with something like, "You know what we could do..." Ideas flew around the room, fueling a full-blown brainstorm. Unfortunately, what followed could best be described as organized chaos. The result was that several of the suggestions took the product back to re-design, and what was supposed to be the final steps didn't happen.

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Elementary, Mr. Watson: Anatomy of Your Component—Footprint, Part 2

09-08-2022

Have you ever gone to a buffet hungry and looking forward to digging in? You grab the plate and start down the food line, picking things as you go. Halfway through, your plate is stacked up with food, looking very similar to the Leaning Tower of Pisa. Then you get to the good stuff at the end of the buffet, but there’s no room on your plate. At this point, you probably feel much like that with the first part of looking at our footprint, but rest assured, although your plate is already full, the good stuff is still waiting for us. I have saved the best for our second offering.

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Elementary, Mr. Watson: The Anatomy of Your Component—Footprint

08-17-2022

I hate to disappoint you if you expect to get everything about footprints from this modest column, but a short search online results in a long list of technical standards and books on this subject. So, I will only hit the surface of the discussion. I have often spoken about the parent-child relationship principle in PCB design. In this series, we have learned that we can see how that "relationship" is supported directly by the information in the component itself. As a short review, the parent-child relationship is where you use an input of data, material, or parts (parents) as the foundation or resource for another item or document (child).

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Elementary, Mr. Watson: The Anatomy of Your PCB Component, Part 2

07-13-2022

In the start of my series of the anatomy of a component, I discussed that the component has two major divisions. The first is information that consists of name, description, parametric information, sourcing (part choices), and the datasheet (Figure 1). Next, the component comprises symbol, PCB footprint, 3D model, and simulation models. I gave the example of the dissection of the frog, with an analogy that every part has a purpose. In the same way, each part of our component has a distinct purpose in our PCB design, including our models.

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Elementary, Mr. Watson: The Anatomy of Your PCB Component, Part 1

06-16-2022

One of the classes I dreaded the most in school each year was biology. This was because I knew it was only a matter of time before I would face the rite of passage for most high school students: dissecting a frog. It wasn’t something I ever looked forward to. We had to go through the same educational exercise and maybe with the same apprehension for most of us. But my point in bringing up the painful experiences of our high school years is, although it was difficult, I did learn a powerful lesson: Every part has a purpose.

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Elementary, Mr. Watson: The Five Pillars of Your Library, Part 5—Traceability

05-12-2022

We have reached the end of this series regarding the five pillars of the component library. We now have a robust library that provides the required resources for the ever-changing industry. Above that is having a flexible library to grow with the company. The final pillar is traceability. Why is traceability so essential and considered a pillar of our library? Read on for details.

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Elementary, Mr. Watson: The Five Pillars of your Library, Part 4—Review

04-14-2022

I trust that you have been enjoying this series on the five pillars of your library. Now that we have a single library managed using our revisioning, and we have lifecycle schemes organized so that we can easily find something in the component category, family, and subfamilies, we are now ready to look at one of our library's most vital principles and pillars: reviewable.

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Elementary, Mr. Watson: The Five Pillars of Your Library, Part 3—Architecture

03-10-2022

Before I continue with the series of the five pillars of your library, I want to do a little review. Although every library is different, the five pillars are consistent with any sound library. You place these pillars to support a specific building section in building construction. To pull one out requires the remaining ones to hold the total weight above. So, each of these supports is needed for your library to succeed. You cannot choose which of them you intend to follow; to pull just one out results in the toppling of the others.

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2021

Elementary, Mr. Watson: PCB Data Management and Security

12-12-2021

As a grandfather of six grandchildren, one of my great joys is spending time with them. There is nothing better than spending an afternoon at the park and especially playing on the teeter-totter. It's all fun and games until grandpa gets on one side, and they try to lift me. Then the harsh reality and a teachable moment in leverage, balance, and just how heavy grandpa really is hits pretty hard.

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Elementary, Mr. Watson: We’ve Never Done It That Way Before

11-11-2021

The September edition of Design007 Magazine discussed the theme of collaborating and working with a team. In that issue, I wrote a feature article called “PCB Design Is a Team Sport.” After that edition was published, I had several follow-up questions and conversations with individuals; they agreed on the importance of teamwork but felt that it's easier said than done. It's challenging because of the inherent problem of team members accepting or handling change very well. Change it's a word that sends shivers down the spine of some. You know those sort of individuals. They're easy to identify. The ones that constantly remind everyone, "We never did it that way before." As if how we did things in the past was so much better.

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Elementary, Mr. Watson: First, Component Shortages, and Now Hot Dogs?

10-14-2021

When I considered the title for this month’s article, I seriously considered calling it "From the Frying Pan Into the Fire" because I’m sure you’ve noticed recently that the component shortage problem has only worsened—we’re now seeing other supply lines breaking down.

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Elementary Mr. Watson: PCB Design—It's a Team Sport

09-29-2021

One of the hard lessons of this past year was about the value of the team and collaboration. I have repeatedly heard how many of us have a newfound respect and appreciation for the teams we work with inside our companies. Out of necessity, we had to find new ways to collaborate.

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Elementary, Mr. Watson: The Danger of Rogue Libraries

09-16-2021

For PCB designers, the most common part of the library is the collection of components used in the PCB design process. But, I have seen some libraries have other information, including a resource area, a group of documents, standards, and articles. So basically it can have anything you want.

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Elementary, Mr. Watson: Epic Fails with Design Rules

08-12-2021

Various sciences, including physics, mathematics, chemistry, are significantly involved throughout the PCB design process, rules that can sometimes be bent but not broken. However, the rules that designers break and ignore altogether and very often are the design rules.

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Elementary, Mr. Watson: Managing Risk in PCB Design

08-05-2021

PCB design is like bungee jumping. With the complexity of a PCB design, the intricate details, and various steps, it's rather easy to make mistakes. Those mistakes, many times, do not show up until it's too late and the board has gone off to fabrication and assembly. By the way, a good rule is not to use your assembly house as your quality control team for PCB designs.

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Elementary, Mr. Watson: Time to Market, from Ludicrous Speed to Plaid

07-18-2021

Mel Brooks may have something to teach us about going "ludicrous speed" in getting our designs to the finish line. John Watson explains.

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Elementary, Mr. Watson: Trust but Verify

06-10-2021

Over many years, I have seen some elaborate PCB library systems. However, the best ones were those not based on the size but rather the quality of the information. That old axiom is definitely “not quantity but rather quality.”

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Elementary, Mr. Watson: Paying the Price To Be a PCB Designer

05-13-2021

Today, the electronics industry is flourishing with innovations and technologies. The result is that the “good” designers are left in the dust. Truthfully, our industry doesn't need more good designers; rather, we need great designers—those who can face any challenge and instead of cowering in the corner, looks at the task at hand and says, "Bring it on."

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2020

Elementary, Mr. Watson: Demystifying Bypass Capacitors

12-17-2020

As PCB designers, we work under the simple rule of cause and effect, and a PCB design can quickly become a petri dish for the butterfly effect to flourish. One of those areas that can quickly snowball into major problems is your PCB power distribution structure. When it goes wrong, it usually goes very wrong and has significant issues throughout your design.

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Elementary, Mr. Watson: Density Feasibility Putting 10 Lbs in a 5-Lb Bag

11-18-2020

Whether on a customer, a system, or a PCB level, it’s essential to understand the final objective and how you intend to get there and meet the customer need at the forefront of any project. In this column, John Watson addresses density feasibility and more.

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Elementary, Mr. Watson: Location, Location, Location

10-15-2020

When it comes to PCB design, one of the most overlooked principles is component placement. Similar to a home, the component location has a considerable impact on the quality and is the real value of a PCB design. John Watson examines five rules to follow when it comes to component placement.

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Elementary, Mr. Watson: Overcoming PCB Designs Pitfalls

09-10-2020

When starting every PCB design, the hope is that we can navigate through any pitfalls that arrive. Unfortunately, many times, issues happen that you do not handle correctly; they fall through the cracks and end up in your PCB design. John Watson explains how that is when the real problems begin.

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Elementary, Mr. Watson: How to Ruin Your PCB Design in 4 Easy Steps

08-06-2020

John Watson has seen firsthand how quickly PCB designs can “go off the rails” by not following a few simple principles. In this column, he looks at four practices that can easily ruin your PCB design.

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Elementary, Mr. Watson: PCB Components Naming Conventions

07-09-2020

How you accurately analyze and identify certain information has a direct connection to the overall success of your PCB designs. In this column, John Watson focuses on the conventional naming scheme for the schematic symbol and footprint to prevent headaches and ulcers later.

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Elementary, Mr. Watson: Collaboration in the PCB Design Process

06-11-2020

The past few months have been trying for everyone, with many of us working from home. However, there are still the underlining principles of collaboration to step into a role to finish the necessary tasks to keep a project moving forward. John Watson, CID, explains.

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Elementary, Mr. Watson: Reinventing Yourself

05-28-2020

When COVID-19 first hit, many businesses were forced to close, and we immediately saw its impact on the service industry. Whatever challenge you’re facing, John Watson emphasizes that it’s time to hit the switch on reinventing.

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Elementary, Mr. Watson: The Positive Side of COVID-19

04-16-2020

With the recent COVID-19 outbreak worldwide, most of us have been forced to reshuffle how we work, live, and play. Something like this has never happened before in our lifetimes, and it is scary and challenging, but difficult times develop resilient people. John Watson shares some of the positive things he has already noticed come out of this situation.

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Elementary, Mr. Watson: Are We There Yet?

03-12-2020

Anyone who has taken a road trip with children knows the question, “Are we there yet?” very well. This question also applies to PCB design. If you are not careful, your PCB project could easily go off track and you could lose sight of what you are doing (objective), why (motivation), how (process), and when (schedule). John Watson emphasizes the importance of these fundamental questions.

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