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The following list of factors, based primarily on Ginsberg,3 must be considered and evaluated in the design of a PB and its assembly:
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Configuration of the PB, size, and form factor(s) Need for mechanical attachment, mountings, and component types Compatibility with EMC and other environmental PBA mounting (horizontal or vertical) as a consequence of other factors such as dust and environment Environmental factors requiring special attention, such as thermal management, shock and vibration, humidity, salt spray, dust, altitude, and radiation Degree of support Retention and fastening Ease of removal
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General Mechanical Design Requirements The general mechanical design requirements for PBs and PBAs include the methods of dimensioning, mounting, guiding during insertion and removal of plug-in components or assemblies, retention, and extraction. Frequently, the PBA mounting method is predetermined as a design requirement to an established compatibility with existing hardware. In other cases, the printed board designer has a choice in determining which PB mounting method is more suitable after considering such design factors as the following:
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PB size and shape based on form, fit, and function requirements Input/output terminations and locations Area and volume restrictions Accessibility requirements Ease of repair/maintenance Modularity requirements Type of mounting hardware Thermal management EMC Type of circuit in its relationship to other circuits
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15.6.1.1 Dimensioning and Tolerancing. The dimensioning and tolerancing system for PBs and PBAs must ensure that the product is appropriately defined for all of the product form, fit, and function requirements for the complete product life cycle, from definition through manufacturing to end use. Dimensioning and tolerancing are critical at least for the design, manufacturing, assembly, inspection, test, and acceptance phases. Regardless of the dimension and tolerance standards that are used to establish and document the product definition s mechanical design and acceptance requirements,4 there should be at least two (primary) data reference features in every PBD (see Fig. 15.1). The purpose is to ensure the integrity of a PB s and PBA s datum reference throughout the production and acceptance process. In general, it should be a nonfunctional hole (in the case of PBs) or a surface feature that is used as the primary datum reference for final dimensional measurements and acceptance of the product. The datum reference should not be a machined edge that is formed in the last phases of the manufacturing, fabrication, or assembly process in a secondary machining operation.
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ELECTRICAL AND MECHANICAL DESIGN PARAMETERS
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FIGURE 15.1 All printed boards and their assemblies should have their datum references included into the design to ensure the integrity of the mechanical datum references throughout a product s production and acceptance cycles.
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15.6.1.2 Mechanically Mounted Printed Board Assemblies (PBAs). PBAs should be mounted to ensure their mechanical (and sometimes electrical grounding) integrity throughout their product life cycle. The following are some of the generally accepted requirements and practices for mechanically mounted PBAs:
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PBAs should be supported within 25 mm of the edge of the PBA on at least three sides. As good practice, fabricated printed boards (PBs) having a thickness of about 0.7 to 1.6 mm should be mechanically supported on 100-mm or lower intervals, and PBs thicker than 2.3 mm on less than 1.3-mm intervals. Fasteners should not be located on less than the PBs thickness or the fastener s head diameter (whichever is lower) from the edge of the PB.
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15.6.1.3 Guides for Printed Board Assemblies. A major advantage of using plug-in printed board assemblies rather than other electronic packaging techniques is the suitability of PBAs for use with mechanical PBA card guides for ease of maintenance, changing configuration, and up-grading function or performance. There are many PBA guide hardware systems that are available either commercially, as industry standard, or proprietarily. The PBA may be predetermined as a design requirement or may be developed based on the size and shape of the PBA, the degree of dimensional accuracy needed to ensure proper mating alignment with the mating connector system, and the desired degree of sophistication. Some PBA guide systems contain a built-in locking system that provides mechanical retention and thermal management (conductive). Caution: Some PBA card guide systems have become somewhat of industry standards and can be obtained or assembled to fit most PBAs. However, not all of the industry-standardlike PBA guide systems are compatible or interchangeable for retaining or extracting PBAs. 15.6.1.4 Retaining Printed Board Assemblies. Quite often, shock, vibration, and normal handling requirements necessitate that the PBA be retained in the equipment by mechanical devices. Some PBA retaining systems are attached as hardware to the PB during assembly; other retaining systems are built into the PBA mounting hardware frequently called a cage. The selection of a proper PBA retaining system is important, since the retaining devices may reduce the amount of PB area available for component mounting and interconnections, and can add significantly to the cost of the electronic equipment.
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