IPC International Community magazine an association member publication
Issue link: https://iconnect007.uberflip.com/i/1546580
66 I-CONNECT007 MAGAZINE I SEPTEMBER 2026 FLEX007 | F L E X C O N N ECT I O N S Copper Tabs: High Conductivity and Versatile Integration Copper tabs are commonly integrated into flexible circuits because they combine excellent electrical conductivity with compatibility across standard as- sembly processes such as SMT and reflow. As the primary conductor used in copper-clad laminates, copper can be incorporated into tab features effi- ciently and with minimal complexity. Advantages of Copper Tabs • Excellent electrical conductivity: Copper offers very low resistance, making it ideal for power delivery, grounding, and signal transfer applications where electrical efficiency matters. • Good solderability and termination flexibility: Copper tabs work well for soldered termina- tions, crimping, and mechanical attachment. Surface finishes such as tin, ENIG, or electro- lytic nickel/gold can be added as well. • Cost-effective: Copper is generally more economical than nickel, especially in high-volume production. Considerations With Copper Tabs Copper is relatively soft compared to nickel and, depending on thickness and temper, can deform more easily under repeated mechanical contact or insertion cycles. It can also oxidize over time if left unprotected. Understanding how the tabs will be used and the environment they will be in can assist in surface finish selection. Common Applications for Copper Tabs • Power distribution and battery interconnects • Voltage sense and temperature sense circuits • Ground tabs and shielding connections • Solderable terminals • Medical devices requiring compact electrical terminations • Industrial assemblies where conductivity is critical. Nickel Tabs: Strength, Wear Resistance, and Environmental Durability Nickel tabs are often selected when the application requires more mechanical durability or environ- mental resistance than copper alone can provide. Nickel offers excellent strength and stiffness while maintaining reasonable conductivity. Advantages of Nickel Tabs • High mechanical strength: Nickel resists bending and deformation better than copper, making it well-suited for applications involving repeated contact or higher insertion forces. • Improved wear resistance: Nickel performs well in contact surfaces where abrasion or friction is present. • Excellent corrosion resistance: Nickel maintains performance in demanding environments involving humidity, chemicals, or temperature cycling. • Dimensional stability: Nickel retains shape well, which is especially valuable when utiliz- ing preformed nickel tabs. Considerations With Nickel Tabs Nickel has significantly higher electrical resistance than copper, so it is generally not the preferred op- tion where maximum conductivity is required. It can also require more specialized surface preparation depending on thickness and attachment method. Common Applications for Nickel Tabs • Battery tabs and pack interconnects • Wear-resistant terminals • Voltage and temperature sensing • Medical devices requiring durable repeated- use contact surfaces • Harsh-environment industrial electronics