Heavy Copper PCB
Heavy copper pcb are used in high power applications like computer, automotive and military control. These circuits can handle extreme heat, elevated temperatures and recurrent thermal cycling that would ruin normal PCBs in seconds.
Fabricators will discuss with customers and match the fabrication process to specific requirements such as layer count, material and etching methods. This will allow them to ensure the design will be able to meet the maximum thickness allowance while still ensuring the prepreg can fill all voids.
Increased Current Carrying Capacity
Current flows through etched copper tracks on a PCB. The current that passes through each track generates heat, which in turn causes the track to expand and weaken. This is why PCB manufacturers use copper traces that are as wide as possible, as well as proper tinning to ensure the highest current carrying capacity possible.
Heavy copper enables PCBs to conduct higher current and achieve good thermal distribution, enabling complex switches to be implemented in limited space. The increased copper thickness also contributes to lower failure rates as the elevated current is able to be dispersed through copper vias and the copper substrate.
PCB fabricators can produce boards with various copper weights, but to qualify as heavy copper a board must contain 3 oz or more of copper on all layers. This improvement in copper weight, along with the right plating and substrate thickness, can transform a flimsy board into a strong, long-lasting wire platform.
The current that runs through a copper trace can be limited by figuring out the optimal signal power, P (W), and voltage, V (Volts) for the circuit operation design. Once the design has been established, the expected temperature rise from current flow can be estimated and then the trace width determined. The expected current is based on the desired maximum current flow and the cross-sectional area of the trace, A (mils2). The temperature rise is proportional to the trace width.
Higher Temperature Resistance
When designing a PCB, the copper thickness and width must be considered. If these parameters are not properly met, a circuit board can experience high-current shocks that can damage appliances. This can cause electrical failure or shorting. Heavy copper pcbs are an excellent choice for higher-current circuit boards because they have increased current heavy copper pcb carrying capacity and can withstand high temperatures for longer periods of time. They also have higher thermal conductivity and can dissipate heat more efficiently than standard circuit boards.
A thicker copper layer can handle high-current loads with greater ease, allowing for larger copper traces and a wider range of applications. This type of circuit board can be used for power transmission in automotive components, rail traction systems and solar power converters.
Thick copper PCBs require specialized etching and plating processes. Depending on the customer’s design requirements, they can be manufactured in a wide range of sizes and layers. It’s important to find a manufacturer that can accommodate your unique needs.
It’s also vital to choose a substrate material that’s appropriate for heavy copper. This must have a low coefficient of thermal expansion to avoid cracking and layer separation, as well as a high glass transition temperature (Tg) to protect the copper from overheating. These factors are especially important for a PCB with high-current applications.
Higher Thermal Conductivity
The circuits on a PCB generate large amounts of heat that can cause the circuit to overheat. The high thermal conductivity of heavy copper plating helps to dissipate this excess heat, which prevents overheating and ensures optimal functioning of the circuit. Additionally, it also reduces the temperature of the component connections.
In addition, heavy copper circuits can be designed with in-built heat sinks that are directly plated onto the board. This eliminates the need for an extra assembly process and saves time and money. However, it is important to consider the thickness of the heat sinks when designing a circuit board with heavy copper plating. Typically, the thicker the heat sinks are, the more heat they will be able to absorb.
For this reason, it is crucial to consult with your PCB fabricator about the proper thickness for your circuit boards. In order to achieve a successful design, it is recommended to work with your fabricator early in the design phase to ensure that the appropriate amount of copper is used.
Heavy copper is also more resistant to heat, cold, and corrosion than other metals. This makes it ideal for use in military and aerospace applications, as well as for high-end electronic products that require exceptional reliability. It is particularly useful in Heavy Copper PCB Supplier power supply circuits, which must withstand high current and voltage requirements as well as extremely low humidity and hot and cold environment conditions.
Increased Durability
Heavy copper PCBs are very reliable, mainly because of their higher current-carrying capacity and the durability of the copper plating used. These features make them ideal for use in applications that require a high level of reliability, such as military and aerospace equipment. These circuit boards are also highly resistant to thermal cycling and can withstand repeated exposure to elevated temperatures.
The process for manufacturing these circuits is similar to that of standard PCBs, involving copper foil, etching, hole drilling, and electroplating. However, different plate thicknesses are used for the planes, pads, and traces. Different differential etching and step plating processes are also required for heavy copper PCBs. These processes allow the copper to be etched with much finer sidewalls and less undercutting.
In addition to these features, heavy copper pcbs are more durable than standard PCBs. They can withstand high-temperature environments and are resistant to vibrations and shocks. Heavy copper pcbs are also capable of conducting current at higher speeds than standard PCBs, which makes them suitable for use in complex devices that need to transfer large amounts of power.
Despite the increased durability of heavy copper pcbs, they may not be suitable for every application. It is best to consult a board fabricator early in the design process to discuss manufacturing tolerances and capabilities. This way, you can be sure that your final product will meet all of your needs.
