Flammability Certification of

Printed Wiring Boards

James M. Peterson
Boeing Commercial Airplanes Group
International Materials Fire Test Working Group
March 5, 2003

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March 5, 2003
 Discussion Points

• Typical Electronic Equipment

• Background
• Plan
• Test Results
• Where We Go From Here

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March 5, 2003
Typical Electronic Equipment
Cooling holes

Circuit cards
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March 5, 2003
Typical Printed Wiring Board

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March 5, 2003
 Typical Electronic Equipment

• Electric Wire
• Printed Wiring Boards (PWBs)
• Cathode Ray Tubes
• Liquid Crystal Displays
• Transformers
• Switches
• Small Components (diodes, resistors, etc.)

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March 5, 2003
 Background
Reasons for Electronic Redesign
• Airline requests for increased functionality
– More features and options
– In-flight entertainment
• Product improvements
– Updates, problem resolution, production improvements
• Component obsolescence
– Cancellation of the military specifications
– Commercial components have a shorter production life due to
high volume users

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March 5, 2003
 Background
Certification Issues
• Certification of PWBs requires FAA 25.853
12-sec vertical Bunsen burner test
• All PWB parts must have certification data
• Certification by “similarity to previously
approved components” currently has limited
FAA acceptance for new PWBs

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March 5, 2003
 Background
Historical
• In the 1960’s, there were only a few electronic
components in the EE bay and flight deck.
– Only self-extinguishing materials compliant to
Military Standards were used
• Today significantly more electrical/electronic
components are used
• Military production standards have been canceled
and replaced by industry production standards
– IPC 4101 has replaced MIL standards for Printed
Wiring Boards (PWBs)
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March 5, 2003
 Background
Current Study
• PWBs tested so far are production boards
– Procured before components were installed
– Full FAA conformity required
– Test results are suitable for certification data
• FAA Technical Center has conducted
parallel tests to corroborate results
• FAA Seattle Aircraft Certification Office
is involved in process planning

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March 5, 2003
 Plan – Develop Process for
Certification by Similarity

• Testing of every PWB part number does not add

value if similarity data can be demonstrated
• Showing compliance by board material
similarity is a significant need for PWBs
– PWBs are in constant redesign
– Most PWB redesign does not change materials
• Software updates
• Re-locating electronic components and
microcircuits
– Baseline testing of PWB and continuous process
control of components provides assurance
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March 5, 2003
 Plan - Objectives

• Classify and test PWBs according to IPC 4101 “slash

sheet” classifications
– Use “slash sheet”, a specification for laminates made
of a particular reinforcing fiber and a particular resin
system, e.g., “/24” refers to an E-glass reinforcing
fiber and FR epoxy resin
– Develop baseline flammability certification data for
PWBs by reinforcing fiber and resin type
– Validate a certification process using similarity of
reinforcing fiber and resin type baseline data and
industry standard specifications
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March 5, 2003
 Plan - Objectives
Flammability
PWB 12-sec vertical test and report
design flammability test

PWB NO Flammability
Laminates certification
NO established?
registered & tested
per IPC 4101 flam* YES
Reqmts.
?
Similarity
Conformal established
YES coating registered to documented
& tested per test NO
YES
UL 94-V0 results
* IPC 4101 paragraph 2.10.3.1 and ? ?
tested per method IPC-TM-650
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March 5, 2003
 Current Activity
• Test matrix basis
– Test PWBs from several manufactures
– Test three PWB thicknesses from each slash
sheet type
– Test PWBs with and without conformal
coating
• Three predominant conformal coatings

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March 5, 2003
 Longer Range Activity
• 13 IPC-4101 resin systems commonly used
– 21, 24, 25, 26, 30, 40, 41, 42, 50, 53, 55, 60, & 71
• Use process to establish certification by similarity for the
predominant resin systems -- 21 and 24
– 21 and 24 (epoxy/glass) have flammability requirements
– 41 (polyimide/glass) has no flammability requirements
Certification by similarity may not be possible.
• Use certification by similarity process for other resin systems
as appropriate
– Work to have International Materials Fire Test Working Group agree
with and endorse the process
• Include in Fire Test Handbook?

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March 5, 2003
 Current Test Plan Matrix
4 laminate 3 Thicknesses 3 conformal
manufacturers coatings
Isola, Double Treat,
Nelco, & Polyclad
resin manuf. Layers Coating 3 samples
system each
21 I Thin Acrylic 3
21
21
D
N
Med
Thick
none
none
3
3
45 PWBs
… … … … … tested
24 N Thin none 3
24 I Med 3
3 resin 24 P Thick
Urethane
none 3 51 PWBs
systems … … … … … yet to be
21, 24, 41 41
41
P
N
Thin
Med
none 3
3
tested
none
41 I Thick Silicone 3
…. …. …. …. ….

96 total
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March 5, 2003
 IPC 4101 Resin Systems
IPC 4101 Glass
Specification Reinforcement Resin System ID Reference Transitio Industry Testing
Sheet # n Range

IPC-TM-650 per
Woven Epoxy, Flame NEMA FR-4, 110°C IPC 4101.
21 E-glass Resistant MIL-S13949/04 Minimum Monthly samples
fabric – GF, GFN, at the laminate
GFK level.
NEMA FR-4, IPC-TM-650 per
Woven Majority Epoxy, MIL-S-13949/04 150°C - IPC 4101.
24 E-glass Modified or – GF, GFG 200°C Monthly samples
fabric Unmodified, at the laminate
Flame Resistant level.

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March 5, 2003
 IPC 4101 Conformal Coating

Conformal Coat Description Boeing Conformal Coat

Flammability Requirements

Type AR (Acrylic) per IPC-CC-830 UL 94 V0

Type UR (Urethane) per IPC-CC-830 UL 94 V0

Type SR (Silicone) per IPC-CC-830 UL 94 V0

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March 5, 2003
 Test Results To-Date
Conformed Testing at the Boeing Facility
IPC
material PWB Laminate Layer Conform Extingushing Time Burn Length
Sheet Manuf. Manuf. s Thickness al coat Test Seconds Inches
1 2 3 1 2 3
1 24 Viasystems Isola 4 .072" none 12 sec 6 0.1 2 0.1 0.1 0.1
2 24 Viasystems Isola 10 .086" none 12 sec 1.4 1.1 1.2 0.9 0.8 0.7
3 24 Viasystems Isola 18 .120" none 12 sec 0 0 0 0 0 0

4 24 Holaday Circuits Double Treat 2 .090" none 12 sec 0 0 0 0.8 1 1

5 24 Holaday Circuits Double Treat 6 .090" none 12 sec 0 0 0 0 0 0
6 24 Holaday Circuits Double Treat 10 .100" none 12 sec 0 0 0 0.1 0.1 0.1

7 24 Tyco Nelco 12 .062" none 12 sec 0 0 0 0 0 0

8 24 Tyco Nelco 14 .079" none 12 sec 4 0 3.1 0.1 0.1 0.1
9 24 Tyco Nelco 14 .091" none 12 sec 0 0 0 0 0 0

10 24 Cosmotronics Polyclad 8 .112" none 12 sec 2 1 1 0.1 0.1 0.1

11 24 Cosmotronics Polyclad 10 .093" none 12 sec 1.3 1.3 1.3 0.2 0.1 0.1
12 24 Cosmotronics Polyclad 12 .100" none 12 sec 1.1 1.8 2.1 0.1 0.1 0.1

13 21 Holaday Double Treat 2 .090" none 12 sec 1.6 1 1 0.7 0.8 0.8
14 21 Holaday Double Treat 6 .090" none 12 sec 0 0 0 0 0 0
15 21 Holaday Double Treat 10 .100" none 12 sec 0 0 0 0.7 0.8 0.7

24 Cosmotronics Polyclad 12 .100" none 60 sec 7 sec 1 in

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March 5, 2003
 FAA Tech Center /24 PWB
12 sec.burn test results (Nov. 2002)

IPC
material PWB Thickn Conformal Extingushing Time Burn Length
Sheet Manuf. Layers ess coat Test Sec Inches
1 2 3 1 2 3
1 24 Viasystems 18 .120" none 12 sec 0 0 0 0 0 0
2 24 Holaday Circuits 6 .090" none 12 sec 0 0 0 0.1 0.1 0.1
3 24 Holaday Circuits 10 .100" none 12 sec < 1 sec < 1 sec < 1 sec < 0.1 in < 0.1 in < 0.1 in
4 24 Cosmotronics 12 .100" none 12 sec 1 1 2 0.1 0.1 0.1

24 Holaday Circuits 6 .090" none 60 sec 0 <0.1 in

24 Viasystems 18 .120" none 60 sec 1 <0.3 in

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March 5, 2003
 Future Testing
IPC material PWB Conformal Extingushing Time Burn Length
Sheet Manuf. Laminate Manuf. Layers Thickness coat Test Sec Inches
1 2 3 1 2 3
1 24 Viasystems Isola 4 .072" Acrylic 12 sec
2 24 Viasystems Isola 10 .086" Urethane 12 sec
3 24 Viasystems Isola 18 .120" Silicone 12 sec

4 24 Holaday Circuits Double Treat 2 .090" Acrylic 12 sec

5 24 Holaday Circuits Double Treat 6 .090" Urethane 12 sec
6 24 Holaday Circuits Double Treat 10 .100" Silicone 12 sec

7 24 Tyco Nelco 12 .062" Acrylic 12 sec

8 24 Tyco Nelco 14 .079" Urethane 12 sec
9 24 Tyco Nelco 14 .091" Silicone 12 sec

10 24 Cosmotronics Polyclad 8 .112" Acrylic 12 sec

11 24 Cosmotronics Polyclad 10 .093" Urethane 12 sec
12 24 Cosmotronics Polyclad 12 .100" Silicone 12 sec

13 21 Holaday Double Treat 10 .086" none 12 sec

14 41 Holaday Double Treat 2 .090" none 12 sec

15 41 Holaday Double Treat 6 .090" none 12 sec
16 41 Holaday Double Treat 10 .100" none 12 sec
17 41 Holaday Double Treat 10 .086" none 12 sec

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March 5, 2003
 To-Date Results
Max Burn
Length = 8 in.

Inches
Max Extinguishing
Time = 15 Sec

/24 /24 /24 /24 /21

Seconds

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/24 /24 /24 /24 /21 March 5, 2003

Typical Burn Lengths

12 sec vertical
Zero” burn
length

60 sec vertical
1” burn
length

12 sec vertical
0.1” burn
length Page 22

March 5, 2003
Typical Burn Lengths

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March 5, 2003
 Existing Individual Board
Certification Test Results
PWB/PWA PWB Industry FAR 25 FAR 25 Burn Length
Description Construction Certifications Test 12 Second Vertical margin of
Method Results pass
Epoxy glass pwb 10 layer UL 94 V0 12 0.0 Second Exciting 86.6%
Material per IPC Second Time
4101/21 or /24 Vertical 0.8 in Burn Length
No Drip
Epoxy glass pwb 12 layer IPC TM 650 12 1.9 Second Exciting 86.6%
Material per IPC Second Time
4101/21 or /24 Vertical 0.8 in Burn Length
No Drip
Epoxy glass pwb 10 layer IPC TM 650 12 0.0 Exciting Time 90 %
Material per IPC Second 0.6 in Burn Length
4101/21 or /24 Vertical No Drip
Epoxy glass pwb 10 layer IPC TM 650 12 0.0Exciting Time 90 %
Material per IPC Second 0.6 in Burn Length
4101/21 or /24 Vertical No Drip
Epoxy glass pwb 10 layer IPC TM 650 12 0.0Exciting Time 99.5 %
Material per IPC Second 0.03 in Burn Length
4101/21 or /24 Vertical No Drip
Epoxy glass pwb 12 layer IPC TM 650 12 0.0 Exciting Time 99.3 %
Material per IPC Second 0.04 in Burn Length
4101/21 or /24 Vertical No Drip
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March 5, 2003
 Existing Individual Board
Certification Test Results
PWB/PWA PWB Industry FAR 25 FAR 25 Burn Length
Description Construction Certifications Test 12 Second Vertical margin of
Method Results pass
Epoxy glass pwb 6 layer UL 94 V0 12 0.0 Exciting Time 99.7 %
Material per IPC Second 0.02 in Burn Length
4101/21 or /24 Vertical No Drip
Epoxy glass pwb 8 layer UL 94 V0 12 0.0 Exciting Time 99.3 %
Material per IPC Second 0.04 in Burn Length
4101/21 or /24 Vertical No Drip
Epoxy glass pwb 12 layer UL 94 V0 12 0.0 Exciting Time 100 %
Material per IPC Second 0.0 Burn Length
4101/21 or /24 Vertical No Drip
Epoxy glass pwb 10 layer IPC TM 650 12 0.0 Exciting Time 90 %
Material per IPC Second 0.6 in Burn Length
4101/21 or /24 Vertical No Drip
Epoxy glass pwb 10 layer IPC TM 650 12 0.0 Exciting Time 91.7 %
Material per IPC Second 0.5 in Burn Length
4101/21 or /24 Vertical No Drip
Epoxy glass pwb 6 layer IPC TM 650 12 0.0 Exciting Time 88.3 %
Material per IPC Second 0.7 in Burn Length
4101/21 or /24 Vertical No Drip

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March 5, 2003