Halogen-Free PCBs: Standards, Benefits and Manufacturing Insights

The electronics industry is moving towards eco-friendly ways of making things. One important part of this change is using PCBs without halogens, which are harmful chemicals. As people worry more about the environment and health, these halogen-free PCBs are becoming very popular. This article explains what they are, why they’re important, and how they’re made. It also talks about PCBONLINE, a company that specializes in making these advanced circuit boards. Firstly, we will understand what actually is a Halogen-Free PCBs?

Definition of Halogen-Free PCBs

Halogen-free PCBs are printed circuit boards that meet strict limits on halogen content, as defined by international standards such as IEC 61249-2-21 and JPCA-ES-01-2003. Specifically, the chlorine (Cl) and bromine (Br) content in halogen-free PCBs must not exceed 900 parts per million (ppm) each, and the total halogen content must remain below 1500 ppm. This restriction ensures that the materials used in the PCB are safer for the environment and human health, as they minimize the emission of harmful substances during manufacturing, usage and disposal.

Importance of Halogen-Free PCB Manufacturing

The importance of halogen-free PCBs extends beyond compliance with environmental regulations. These PCBs support green initiatives by reducing toxic emissions and enabling the recycling of electronic components. Standards such as IEC 61249-2-21 and JS709C set benchmarks for environmentally responsible PCB manufacturing. By adhering to these guidelines, companies can reduce their ecological footprint and align with global efforts to combat climate change.

Overview of PCBONLINE’s Halogen-Free Capabilities

PCBONLINE has established itself as a leading provider of halogen-free PCB solutions. The company offers turnkey manufacturing services, producing halogen-free PCBs with advanced materials, meticulous quality control and state-of-the-art production technologies. From rigid and flexible PCBs to specialized RF and microwave boards, PCBONLINE ensures that its halogen-free offerings meet the highest standards of performance and reliability.

Why Choose PCBONLINE for Halogen-Free PCB Manufacturing?

Comprehensive Halogen-Free Process

PCBONLINE adopts a holistic approach to halogen-free PCB manufacturing, ensuring that every step—from material sourcing to final packaging—is fully compliant with halogen-free standards. Stringent material quality checks are conducted to verify halogen content and precise labeling practices are implemented to guarantee traceability.

State-of-the-Art Equipment

The production lines at PCBONLINE are designed exclusively for halogen-free manufacturing. Specialized machines segregate and label halogen-free materials, maintaining strict compliance throughout the production process. This advanced infrastructure ensures consistency and quality in every product.

Expert Team

PCBONLINE’s dedicated team of engineers provides one-on-one support to address specific halogen-free requirements. Customers also benefit from free Design for Manufacturing (DFM) services, which optimize designs for halogen-free production while ensuring cost-efficiency and performance.

Certified Quality Assurance

PCBONLINE provides comprehensive quality assurance, including halogen-free SGS test reports and Material Safety Data Sheets (MSDS) for all components used. These certifications offer transparency and build confidence in the reliability of the company’s products.

Custom PCB Manufacturing

PCBONLINE offers a wide selection of halogen-free laminates and customizable PCB options to meet diverse application needs. Whether for consumer electronics, automotive or industrial systems, the company delivers tailored solutions with exceptional precision.

Efficient Logistics

Global customers can rely on PCBONLINE’s efficient logistics network, which includes partnerships with DHL, FedEx, and UPS. These multiple shipping options ensure timely delivery, regardless of location.

What Does Halogen-Free Mean for PCBs?

Halogens are a group of elements in the periodic table, including chlorine (Cl), bromine (Br), fluorine (F), iodine (I), and astatine (At). In PCB manufacturing, halogens have traditionally been used as flame retardants to enhance the fire resistance of materials such as FR4 and CEM-3 laminates.

Environmental and Health Concerns

When halogen-containing PCBs are incinerated or exposed to high temperatures, they release harmful substances such as dioxins, benzofurans and hydrogen bromide (HBr). These toxic emissions pose significant risks to both human health and the environment, including air and water pollution.

Halogen-Free Requirements for Electronic Components

To address these concerns, halogen-free PCBs replace traditional halogen-based flame retardants with alternatives such as phosphorus (P) and nitrogen (N) compounds. These materials offer comparable fire resistance while eliminating the environmental and health hazards associated with halogens.

Current Regulations and Trends

While regulations such as the EU RoHS directive have banned certain halogenated compounds (e.g., PBB and PBDE), the transition to fully halogen-free electronics remains a voluntary initiative. However, the trend is gaining momentum as manufacturers and consumers prioritize sustainable practices. Halogen-free PCBs are increasingly becoming the standard for high-performance, eco-friendly electronic products.

Halogen-Free PCB Manufacturing Measures

Material Selection

• Use of Phosphorus and Nitrogen-Based Flame Retardants:
  In halogen-free PCBs, traditional halogen-based flame retardants such as bromine and chlorine are replaced with phosphorus and nitrogen-based compounds. These alternative materials provide effective flame resistance while complying with environmental standards.
• Ensuring Supplier Compliance with Halogen-Free Standards:
  Manufacturers must ensure that raw materials sourced from suppliers meet halogen-free certification requirements, such as those specified by IEC 61249-2-21 and JS709C. Regular audits and quality checks of suppliers are integral to maintaining compliance.

Production Process

• Dedicated Production Lines to Avoid Cross-Contamination:
  Halogen-free PCB manufacturing involves separate production lines exclusively used for halogen-free materials. This segregation minimizes the risk of contamination from traditional PCB materials containing halogens.
• Regular Testing of Materials for Halogen-Free Certification:
  Continuous testing of raw materials and finished products is conducted to verify adherence to halogen-free standards. These tests ensure that chlorine and bromine levels do not exceed the permissible limits of 900 ppm, with a total halogen content under 1500 ppm.

Packaging and Storage

• Proper Labeling of Materials and Finished Products:
  All materials and PCBs are clearly labeled as halogen-free during storage and shipment. This ensures that they are easily identifiable and kept separate from non-compliant materials.
• Separate Storage Areas to Maintain Halogen-Free Integrity:
  Dedicated storage areas are used for halogen-free materials and products. This prevents cross-contamination and ensures that halogen-free integrity is maintained throughout the supply chain.

Advantages of Halogen-Free PCBs

Here are some advantages of using Halogen-Free PCBs:

Environmentally Friendly

• Reduced Toxic Emissions During Fire Exposure or Recycling:
  Unlike halogen-containing PCBs, halogen-free PCBs do not release toxic dioxins or other harmful gases when burned. This makes them safer for the environment and for humans during manufacturing, use, and disposal.

Improved Thermal Properties

• Lower Thermal Expansion:
  Halogen-free PCBs have a lower coefficient of thermal expansion, which enhances their dimensional stability and reliability in high-temperature applications.
• Longer Delamination Times and Higher Decomposition Temperatures:
  The phosphorus and nitrogen-based flame retardants used in halogen-free PCBs contribute to longer delamination times and higher decomposition temperatures, making these PCBs suitable for demanding environments.

Better Stability

• Lower Water Absorption:
  The molecular structure of halogen-free materials reduces the likelihood of forming hydrogen bonds with water molecules, leading to lower moisture absorption rates compared to traditional PCBs.
• Enhanced Thermal Stability:
  Halogen-free PCBs exhibit improved resistance to thermal cycling and mechanical stress, ensuring better performance and longevity in applications with high thermal demands.

Halogen-Free PCB Manufacturing Capabilities at PCBONLINE

PCB Specifications
PCBONLINE offers versatile manufacturing capabilities to meet the most demanding halogen-free PCB designs. Their capabilities include:

• Layers: From single-layer to 64-layer PCBs for various applications.
• Thickness: Options range from 0.15mm to 3.2mm, ensuring compatibility with diverse designs.
• Copper Thickness: Customizable from 1/3oz to 6oz, catering to applications that demand varying current capacities.

Supported Materials
PCBONLINE uses high-performance halogen-free materials, such as:

• FR4 for general-purpose applications.
• Aluminum and ceramic for superior thermal management.
• Teflon and polyimide for high-frequency and flexible designs.
• Copper substrates for enhanced electrical and thermal conductivity.

Laminates
They support industry-standard laminates, including:

• Shengyi, Isola, TUC, ITEQ, and Ventec, ensuring reliability and compliance with halogen-free requirements.

Standards and Certifications
PCBONLINE adheres to international environmental and safety standards, such as:

• IEC 61249-2-21: Defining halogen-free materials for printed circuit boards.
• JS709C: Compliance with halogen-free benchmarks for electronics manufacturing.

Surface Finishes
To ensure excellent performance and reliability, PCBONLINE provides various surface finish options:

• ENIG (Electroless Nickel Immersion Gold) for corrosion resistance and solderability.
• Immersion Silver for high conductivity.
• Immersion Tin and other specialized finishes for specific use cases.

Applications of Halogen-Free PCBs

Halogen-free PCBs find application in numerous industries due to their safety and environmental benefits. Key applications include:

• Automotive Electronics: Engine control units, safety systems and infotainment devices.
• Communication Equipment: Routers, switches and base stations requiring high reliability.
• Smartphones, Computers, and Tablets: Consumer electronics where compactness and performance are critical.
• LED Lamps and Display Screens: Ensuring eco-friendly lighting and visualization solutions.
• DC/DC Converters: Power conversion systems in industrial and consumer devices.
• Electronic Gaming and Entertainment Systems: Circuit boards used in gaming consoles and entertainment hubs.

Final Words

Halogen-free PCBs offer unparalleled advantages, including environmental safety, enhanced performance and compliance with evolving regulations. They play an imp. role in promoting sustainable and responsible electronics manufacturing.

PCBONLINE simplifies the process of manufacturing halogen-free PCBs by providing a one-stop solution for both prototyping and mass production. Their advanced facilities, certified materials and professional support ensure a seamless and compliant experience for customers worldwide.

Contact PCBONLINE today for all your halogen-free PCB needs.

Visit website – PCBonline.com  OR
📧 Email: info@pcbonline.com