PCB Connection Technology

In modern electronics manufacturing, the choice of PCB connection method directly impacts product performance, reliability, and production costs. Statistics show that approximately 35% of early PCB failures are related to improper connection process selection. This article provides an in-depth analysis of three mainstream PCB connection technologies – V-Cut, Mouse Bites, and Hollow Bridges – to help engineers make optimal choices.

1. Detailed Analysis of V-Cut Technology

Process Characteristics

V-Cut involves precision milling of V-shaped grooves (typically at 30-45 degree angles) on both sides of the PCB, leaving about 1/3 of the board thickness as connecting bridges. This process is particularly suitable for FR-4 materials with thicknesses of 0.6-3.0mm, achieving a minimum board edge spacing of 0.8mm.

Key Advantages

1. Production Efficiency: 800-1200 cuts per hour, ideal for mass production
2. Cost Effectiveness: Saves approximately 15-20% in processing costs compared to mouse bite technology
3. Mechanical Strength: Retained connecting bridges can withstand 5-8kg of bending force

Design Specifications

• Groove depth tolerance: ±0.05mm
• Position accuracy: ±0.1mm
• Residual thickness: 1/5-1/3 of board thickness (recommended value)

Pro Tip: For high-frequency circuits, maintain at least 3mm distance between V-cut lines and nearest traces to avoid signal integrity issues.

2. In-Depth Analysis of Mouse Bite Technology

Process Implementation

Mouse Bites use an array micro-hole design (typically Φ0.3-0.8mm) with hole spacing of 1.0-2.0mm. Modern laser drilling achieves ±25μm hole diameter accuracy.

Outstanding Features

1. Signal Integrity: Reduces signal attenuation by about 18% at 10GHz compared to V-Cut
2. Design Flexibility: Supports irregular board separation, such as curved edges
3. Secondary Development: Holes can be directly used as mounting positioning holes

Key Parameters

3. Analysis of Hollow Bridge Technology

Innovative Process

Hollow Bridges use precision milling + conductive adhesive filling process, with typical slot widths of 0.2-0.5mm and aspect ratios up to 3:1. Latest nano-silver conductive adhesives achieve <10mΩ connection resistance.

Unique Value

1. Space Utilization: Saves 40% of space compared to traditional connections
2. Thermal Management: Thermal conductivity up to 5W/mK
3. Reliability: Passes 1000 thermal cycles (-40℃~125℃) testing

4. Technology Comparison and Selection Guide

Comprehensive Performance Comparison Table

Selection Decision Tree

1. High-Frequency Applications → Prioritize Mouse Bites
2. Cost Sensitivity → V-Cut is the best choice
3. High Reliability Requirements → Consider Hollow Bridges
4. Complex Shapes → Mouse Bites offer more flexibility

5. Extended Reading on Key PCB Performance Metrics

When selecting connection methods, also consider these key parameters:

1. Dielectric Constant (Dk): Affects signal propagation speed
2. Loss Factor (Df): Determines high-frequency signal attenuation
3. TG Value: Reflects material temperature resistance
4. CTE: Coefficient of thermal expansion matching

6. Future Development Trends

1. Hybrid Connection Technologies: V-Cut + Mouse Bite combinations can improve performance by 15%
2. Laser Microprocessing: Enables precision connection structures below 50μm
3. Embedded Connections: Innovative applications of 3D printed conductive structures

Conclusion

Selecting the appropriate PCB connection method requires comprehensive consideration of electrical performance, mechanical strength, budget constraints, and production conditions. Engineers are advised to conduct comparative tests of at least three connection methods during prototyping, collecting actual data before making volume production decisions. With the development of 5G and IoT technologies, innovation in connection processes will become an important breakthrough point for the PCB industry.