"Shrinky Dink"

I had some "Shrinky Dinks" when I was a kid. Amazingly you can still buy them. You can also use that concept in your prototyping. I did that recently. I have a robot board design that I'd like to shrink about in half and add in a LiPoly charger chip. Most of the design came from something I had built previously, but the charger chip was new to me as was the compression needed to meet my size goals. Sadly, you can't just put your PCB in the oven and have it shrink like a Shrinky Dink. Maybe if you could put stretchy copper traces on it so they wouldn't peel of while the substrate shrinks...

The charger comes in both DFN-10 and MSOP-10 packages and the MCU comes in SOIC and QFN packages. The QFN is the 44 pin version while the SOIC is the 28 pin version of the chip. Same core. Just more I/O.

LBDC Li LBDCmini pRather than test my ability to shrink and the use of the LiPoly charger at the same time, I added it into the original design without changing the size. There's much more room for probing or even for adding test points if I needed them. Once that design checked out okay (which it did), I just went into the schematic editor, changed the SOIC to the QFN package, the MSOP to the DFN and most of the passives to 0402 packages. I really didn't have to make any changes to the schematic.

That almost worked perfectly. The 28 pin MCU doesn't come in a variant with a QFN package, so I couldn't just change the package type in the schematic editor. I had to delete the SOIC version, place and wire in the 44 pin QFN variant. I made a few other changes too. I added in a QFN packaged RS232 driver and a hard power switch. In the original, I had envisioned a soft power switch but I changed my mind. I also had to modify the library parts to make sure that the solder paste layer on the QFN and DFN parts fit our guidelines. Lastly, I removed some LEDs that I only had on the board for debugging purposes.

The most important two considerations were watching out for physical part interference and getting the paste layer correct on the QFN/DFN parts.

Duane Benson
It's the size of a small walnut


LiP DFN unstuffedIn the land of protorypes, sometimes "close enough" is good enough. That can save money on PC boards and assembly when a particular package version of your part is out of stock. But, it's not universal. Sometimes you can't go that way.

I've got an MCP78338 Li Poly charger chip. It comes in 10-DFN and 10-MSOP packages. I originally used the MSOP version on my first PCB pass. Everthing worked just fine, so I re-layed out the board to be about half the area. That meant that wherever possible, passives went from 0603 to 0402 and chips went from whatever to QFN/DFN pacakges.

LiP MSOP on DFN padUnfortunately, the DFN package Li Poly charger seems to be out of stock with long lead times. That got me looking at my options. Option 1, would of course be to just wait. Option 2 would be to re-lay out the board for the MSOP part in that space. Option three is to use the "we'll make it fit" mantra. There are no gurantees at this point, but sometimes it's worth a try.

But... Twas not to be. If you look at the second image, you can see that the footprint of the MSOP part leads is wider than the land pads for the DFN. I suppose there are still a few really messy and potentially expensive options You could solder a small wire on to the pads, sticking out from the pads, effectively making them big enough to accomodate the chip. Very ugly, but might work. Probably too spendy though.

Duane Benson
Carpe DFN

QFN Solder Paste Layer

LBDCminiI've got the fab order placed with Sunstone.com for my next demo project. The little board is represented here at pretty close to actual size on screen - provided you have a 22" monitor set at 1680 pixel horizontal resolution. Give that, you might want to click on it to pop up a bigger representation of it. That makes it about 4 X life size.

When you do that, take note of the QFN / DFN parts: The processor in the middle, the LiPoly battery charger right between the upper two mounting holes and the RS232 driver in the lower left. I've followed my paste layer advice and segmented the paste stencil layer to reduce the chance for float or major voids.

I found a footprint in the library for the big processor in the middle. I just had to modify the paste layer, as shown here. I made the footprint for the charger and RS232 chips from scratch. Neither had anything close enough in the library.

The DFN has a slightly different approach to segmenting the stencil layer. Little squares like I used on the other two chips work just as well, but this is effective as well.

Another thing to take note of is the markation on the LEDs. The original footprint for the 0402 LEDs does have a polarity mark, but it's one of the types that can easily be misinterpreted or can be difficult to see. The diode symbol put down in silk screen removes any possibility of ambiguity.

Duane Benson
I'm happy I live in a split level head.


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