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3.5.3 Base Material Repair, Edge Transplant Method

  • This procedure is used to repair mechanical or thermal damage to circuit board base material.
  • Cut away damaged base material with a saw or milling cutter.
  • Cut a groove into the edge of the circuit board.
  • Mill a tongue onto the edge of the replacement base material.
  • Check fit of new base material and bond in place with epoxy.
  • Trim the excess material with a saw or milling cutter.
  • Complete the repair by drilling holes and applying coatings as required.
Outline
This procedure is used to repair mechanical or thermal damage to circuit board base material. This method is used when extended areas of base material must be completely replaced. This method may be used on single sided, double sided or multilayer circuit boards or assemblies.

Caution
Surface circuits may need to be replaced in the damaged area. Be sure that the appropriate circuit diagrams, or photographs reflecting the original circuits are available so that they may be replaced after repairing the base board material. Damage to internal circuits or planes may have to be restored using surface wires.

Minimum Skill Level - Expert
Recommended for technicians with advanced soldering and component rework skills and extensive experience in most repair/rework procedures.

Conformance Level - High
This procedure most closely duplicates the physical characteristics of the original, and most probably complies with all the functional, environmental and serviceability factors.

Acceptability References
IPC-A-600 2.0 Externally Observable Characteristics
IPC-A-610 10.0 Laminate Conditions
Procedure References
1.0 Foreword
2.1 Handling Electronic Assemblies
2.2 Cleaning
2.3.1 Coating Removal, Identification Of Coatings
2.4.1 Coating Replacement, Solder Mask
2.4.2 Coating Replacement, Conformal Coatings/Encapsulants
IPC7721 3.5.3 Base Material Repair, Edge Transplant Method
Tools and Materials
CircuitMedic Part
Alcohol Swab
Self-saturating Isopropyl alcohol swab. Squeeze handle to release alcohol.
CircuitMedic Part
Ball Mills, Abrasives, Cutting Tools
Ball mills, abrasives and cutting tools for working on circuit boards.
CircuitMedic Part
Cleaning Brushes
Disposable brushes for use with solvents for cleaning and application of coatings.
CircuitMedic Part
Circuit Bond Packs
Clear, superior strength epoxy in two-compartment plastic packages
CircuitMedic Part
Foam Swab
Ideal for absorbing cleaning solvents, and applying color agents and epoxies.
CircuitMedic Part
High Temp Tape Discs
High temperature polyimide tape discs, .50" diameter.
CircuitMedic Part
Knife with #16 Blades
A must-have tool for precise cutting, scraping and trimming.
CircuitMedic Part
Micro Drill System
Versatile power tool for milling, drilling, grinding, cutting and sanding circuit boards.
CircuitMedic Part
Scraper
Hardened stainless steel tip for scraping solder mask and removing defects.
Images and Figures
3.5.3  Base Material Repair, Edge Transplant Method
Damaged Base Material
3.5.3  Base Material Repair, Edge Transplant Method
Figure 1: Cut away damaged base material with a saw or milling cutter.
3.5.3  Base Material Repair, Edge Transplant Method
Figure 2: Cut a groove into the edge of the circuit board.

3.5.3  Base Material Repair, Edge Transplant Method
Figure 3: Mill a tongue onto the edge of the replacement base material.
3.5.3  Base Material Repair, Edge Transplant Method
Figure 4: Check fit of new base material. The tongue must mate with the groove in circuit board.
3.5.3  Base Material Repair, Edge Transplant Method
Figure 5: Trim the excess material with a saw or milling cutter.

3.5.3  Base Material Repair, Edge Transplant Method
Figure 6: Complete the repair by drilling holes and applying coatings as required.
Procedure
  1. Clean the area.
  2. Cut away the damaged board material using the Saw or milling cutter. Remove all evidence of the damaged material. No fibers of laminate material should be exposed. File the edge to ensure that the edge is flat. (See Figure 1)

    Caution
    Exercise care to avoid damage to any internal conductors. If any internal conductors are damaged, surface wires may be required to restore electrical connection.
  3. Clean the area.
  4. Install a carbide saw into the Micro-Drill System. Set the speed to maximum and machine a groove in the edge of the circuit board where the new base material will be installed. The groove must be centered in the edge to ensure that the new piece will fit properly. The groove width should be approximately 1/3 of the PC board thickness. The groove depth should be approximately double the groove width. (See Figure 2)
  5. Cut a piece of replacement base board material that is the same thickness and type as the piece removed. The replacement piece may be over-sized, the excess material will be removed after the replacement piece has been epoxied in place.
  6. Install an end mill into the chuck of a milling machine. Machine a tongue onto the entire mating edge of the replacement base material. The dimensions of the tongue should match the size of the milled groove. (See Figure 3)
  7. Where required apply High Temperature Tape to protect exposed parts of circuit board bordering the prepared area.
  8. Check the fit to be sure the new base material properly mates with the groove in the circuit board. (See Figure 4)
  9. Mix the epoxy.
  10. Coat both the tongue and groove surfaces with epoxy and fit together. Remove excess epoxy.
  11. Cure the epoxy per Procedure 2.7 Epoxy Mixing and Handling.
  12. After the epoxy has cured remove the High Temperature Tape.
  13. If needed, scrape off any excess epoxy using the knife or scraper.

    Note
    If needed, apply additional thin coating to seal any scrapped areas.
  14. Saw or mill off excess base material and file flush with existing edge. (See Figure 5)
  15. Clean the area.
  16. Complete by drilling holes, slots, etc. or adding circuitry as required. (See Figure 6)
  17. If needed, replace solder mask or conformal coating. (See Figure 6)
Evaluation
  1. Dimensions of area replaced should be checked to conform to specifications required.
Procedure for reference only.
 

Related Products

115-1322 Circuit Bond Kit
Kit containing packages of clear, low viscosity, superior strength epoxy for circuit board damage repair.
201-3110 Base Board Repair Kit
Kit to repair base board and laminate damage on circuit boards.
Color Agents
One part, air-drying, semi-paste ink for printing on hard surfaces and used to tint the color of epoxy.
Customer Comments
We just received our repair circuit boards. They look great. Nice job!!"
J.M. Wilmington, MA USA
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