Heavy Copper PCB
Heavy copper pcb are a growing trend in PCB design. They have higher copper weight than standard PCBs and can withstand more current. This makes them an excellent choice for high-power applications. However, designers must understand the physics involved before designing for this type of board.
Increasing the width of traces will increase the current carrying capacity of the PCB, but this can cause excessive heat. This can damage the circuit and shorten its life.
Cost
When designing a heavy copper PCB, you need to consider several factors. First, the thickness of the copper layer is important. The higher the copper thickness, the more expensive it will be to produce. The heavy copper pcb next factor is the number of layers in your PCB. Typically, heavy copper PCBs are multi-layered and can be made in either single-sided or double-sided configurations. A single-sided PCB is less expensive, but it may not be suitable for your application.
The manufacturing process for heavy copper PCBs is a little more involved than standard FR4 boards. Before sending the PCBs to production, an engineer checks the design. This step is called Design for Manufacture (DFM) testing, and it helps ensure that the board meets the required tolerances.
After the design is verified, the boards are sent to the fabricator for construction. The final product is then tested for electrical reliability. Once the board passes this test, it’s ready for delivery to the customer.
Heavy copper PCBs are used for high-current applications, including power converters and planar transformers. Their thick copper plating allows them to combine high-current circuits with control circuits on a single PCB, and their high-temperature materials help reduce the chance of failure. The copper’s high conductivity also helps pull heat away from sensitive components, minimizing damage and extending component life.
Design
Heavy copper PCB technology enables complicated switches to be placed in a limited space. It also enables the circuitry to cope with high current levels and improves heat dissipation. This PCB is usually a multi-layered or double-sided board with detailed layout structures on the external layers and thick coppers layers in the internal layers. This type of PCB is widely used in power converters and planar transformers.
A heavy copper PCB requires a special manufacturing process and is more expensive than standard copper PCBs. The cost is mainly due to the increased copper weight and extra chemicals needed to produce it. In addition, the etching process can be long and requires more time to complete. However, the extra cost is well worth it because it offers superior performance.
The thickness of the copper traces in a PCB determines its resistance and ability to conduct heat. This is why it’s important to design a PCB with the right copper thickness. Besides, the copper’s surface should be as smooth as possible to prevent damage during the fabrication process. In addition, you should consider the relationship between Minimum Line Width and Minimum Line Space when designing your PCB.
Heavy copper PCBs are ideal for high-density electronic products that require high-speed communication and processing capabilities. They can also tolerate higher temperatures and recurrent thermal cycles. These features make them more suitable for use in computer, automotive and military control applications.
Manufacture
The manufacture of a heavy copper PCB is a specialized process. This is because the copper layers in this type of circuit board are thicker than standard ones, which enables the circuit to carry high currents. In addition, the PCB has excellent thermal management capabilities. This makes it ideal for military and aerospace applications, where the board must withstand extreme temperatures.
In order to create a heavy copper PCB, manufacturers must use different etching and plating techniques to achieve straight edges. The copper thickness of the plated through holes is also increased to ensure that they can withstand high mechanical loads. These characteristics make heavy copper PCBs suitable for a variety of applications, including EV-chargers and power storage systems.
During the fabrication process, a lithography step is used to mark the component positioning and instructions. Then, automated machines are used to attach the components to the marked locations. After the components are attached, a heat treatment called reflow is used to melt solder paste and bond the components to the PCB.
After the components are attached, the PCB is inspected and tested to ensure that it meets the customer’s requirements. Once the PCB has been tested, it is packaged and shipped to the customer.
Quality
Heavy copper PCBs have been used for many years in military and aerospace applications, but they’re now gaining popularity in a variety of mainstream electronics. This is because they can handle high currents and can disperse heat efficiently. These thicker copper circuit boards are also more tolerant to temperature and humidity, making them a great choice for use in harsh environments.
The thickness of a heavy copper PCB can vary from 1oz to 3oz, and can be made in single-sided, Heavy Copper PCB Supplier double-sided, or multilayer configurations. The manufacturing process is similar to standard PCBs, but the copper layers are much thicker. The thicker copper also requires specialized plating and etching techniques to accommodate its thickness. This can lead to higher costs for the finished product, but it allows the manufacturer to design the circuit board with more current-conducting material in a smaller area.
A heavy copper PCB can carry more current than a standard printed circuit board, but the designer must consider the amount of heat the circuit board will generate when designing it. This includes calculating the copper thickness, trace width, and maximum temperature rise. A tool can help you calculate these parameters, but it’s important to consult a PCB engineer to ensure that your design is accurate.
The copper in a heavy copper PCB can also be formed to have straight sidewalls and negligible undercutting, which is difficult with standard copper clad laminates. Additionally, the increased thickness of the copper enables the PCB to be more resistant to temperature and chemical degradation.