Creating a Thermal Cycling Rig for Testing Copper Via Rivets

I am creating a rig to test the reliability of Copper Via Rivets. IN PROGRESS..

Latest Update: I’ve re-done the temp sensors using cat-6 twisted pair cable and some other components.  When I can I’ll post pictures.

Update:  I’ve been having problems with the temp sensors reading unreliably.  I’ve tried several things to fix this, but really I have been trying to fix it blind, which is a bit of a pain and somewhat discouraging.  What I really needed was an oscilloscope to be able to really see what’s happening.  The one I found was about $355 on Amazon: Rigol DS1052E 50MHz DSO

I found another site where I could order it with free shipping for $336. It only took 10 days to receive the scope shipped from Hong Kong to near Los Angeles, from bestofferbuy.com.  Their standard shipping included a USPS tracking number that worked fine.  I’m impressed with it.  The only issue was they sent it with a “China standard” plug… but the socket on the side of the scope takes a standard computer cord… no problem.

The interesting thing about this scope is that it can be switched to a 100 mhz scope by changing it’s model number etc using the USB port – the same hardware was used for both models!  I’ve done it, no problem. This blog tells how.

This project will now continue, since I’ve figured a way out of my dilemma.  I need to re-make the test board, and test a slight improvement in riveting while I’m waiting for the scope to arrive.

Update: I found some interesting information on the causes of thermal cycling induced failures in industry standard plated vias. According to this article the failure is due to weakness in the plated via wall, and that strengthening the via wall can eliminate the failures and can constrain the relatively weak expansion forces of the laminate. We will see if copper rivets will also behave as stronger vias (being many times stronger since they are solid).

Purpose: to determine if copper via rivets will fail due to thermal cycling.  Assembly and programming are complete, and the test board is complete.  Continue reading…

Double Sided Test Board ready to etch. This board will have 100 riveted vias in series.

Finished Test Board

Alibre Design – a Great Parametric CAD program

I love this program!  After looking at many different CAD packages I decided on Alibre Design over a year ago – the Personal Edition was $100 then, and it’s more now.

It has a very good sketch mode with parametric dimensioning that stays intimately connected to each object, and you can re-dimension at will. It was a bit of a learning curve, but there are a lot of vids that help a lot, and its well worth the time.

Read More…

You Can Get Your Glasses Online and Save Big Bucks

I recently needed to replace my glasses and found there is a massive markup for glasses frames and lenses.   How much do you think?  100%, 200%?  How about 1000%!!

I found you can order good glasses online with your prescription for as little as $16 or less with shipping.  Yes, it takes about two weeks to receive them, fine!  The usual markup on anti-reflective coating is just as bad, it cost me $50 from my optometrist last time, but costs only $5.00 online.   I was shocked!   Read more…

DIY Dextrin Coated Paper for the Toner Transfer Method

I have added a page about How to make Dextrin coated paper for Toner Transfer.

DIY Riveted Vias

I have developed a method for easily and cheaply creating riveted Vias for circuit boards.

• A Via is a connection that goes from one side of a PCB to the other.  There are times that you want to electrically or thermally connect the two sides of a board, and a regular commercial or soldered Via will not work – for instance a via in a home-made board may be under a chip and must be flush, or one is in a SMT pad and you don’t want the solder to wick down a via hole, or the via may need better thermal or current carrying capabilities.  Here is the full article, now updated with more photos.

Update: I am building a test board with 100 vias in series, and a Themal Cycling Test Rig to determine if thermal cycling will cause failures in these kind of copper via rivets in FR4.  See above.

Perfect single or double sided PCBs with the Toner Transfer Method

Link

I discuss my method of creating perfect single or double sided PCBs using the Toner Transfer Method.

Click for full article

My prototype A3987 stepper motor controller (50v 1.5A) with riveted thermal vias, with added 1/2 current semi-sleep mode, and 8 status LEDs (my first SMT board so the soldering is not perfect).

 

DIY Electronics and Audio Links

Rod Elliott’s excellent website.  This is where I learned about Bi-Amplification.

Open Circuits

Electronic Component Vendors

Electrical Calculators

Ohms Law Calculator

Picofarad to Microfarad Calculator

LED Series Resistance Calculator

Custom Fit Earbuds

I followed Collin’s instructions for making custom fit earbuds:  Youtube link

It all worked exactly as he said.  They sound much better than the Apple iPhone earbuds. They are very comfortable, I can wear them for hours.  MidwayUSA has the earplug kits in various colors for $11.99.

Update: I noticed after a month that I was loosing all sound in the left earbud, so I tried cleaning it with peroxide, and then alcohol, and got only temporary results.  I ended up removing the little screens at the earbud openings, and found there is a little fiber pad behind each screen, stuck to it.  This pad can easily become clogged.  I left the screens off and the sound was back full volume.  However, the buds now have high peaks at the upper end – I measured the Frequency response using a reference microphone – way too much highs.  I will post more about this after I build a sound isolating box to test the buds in.  I will be looking for some new buds…

Update: I got some earpods with my iPhone 5, love them.  End of story.

My Ultimate HIFI Subwoofer

This subwoofer is the first completed component of my Tri-amp Surround project.

Detail Pages:

Subwoofer Design,  Building the box,  Building the Corner Coving, Building the Straight Coving,

Coving the Interior,  Finishing, Final assembly, Final thoughts