Heavy Copper PCB
PCBs with heavy copper are used to carry large power components and have high current capacity. They are also more rugged and can withstand repeated thermal cycling that can ruin standard PCBs in seconds.
However, heavy copper designs can be difficult to fabricate. A good working relationship between the designer and fabricator is essential to success.
Cost
PCBs are a crucial component of almost all electrical products, equipment and appliances. They create a compact path for current to flow through the circuit, and they are also responsible for regulating the temperature of the device. However, some products require a heavy current flow that exceeds the capacity of standard PCBs. For this reason, they need a thicker copper/conductive layer. Heavy copper PCBs are available in various thicknesses and sizes to meet different product needs.
These boards have a large copper layer, and their finished copper weight is over 4oz (140mm), which is more than the 1oz or 2oz that are found on regular PCBs. This extra copper allows the board to carry more power and establish high thermal circulation. It is also suitable for complex switches that need to fit into a small space.
The cost of a heavy copper PCB is higher than that of a regular one, but it is worth the investment because of its advantages. If you’re considering purchasing a thick copper PCB, contact several manufacturers to find out what their pricing is. You can then choose the best manufacturer based on your specific requirements and quality standards.
When choosing a manufacturer for your heavy copper PCBs, make sure that they have the necessary experience and capabilities to produce heavy copper pcb high-quality boards. It is also important to ensure that they have a good reputation and are known for meeting industry standards.
Performance
Heavy copper PCBs are a popular solution for electronic equipment with high power density, as they can handle higher current loads and lower thermal strain. They also allow for better heat dissipation and can reduce the need for additional cooling systems in the device. However, the increased copper thickness comes with a cost: higher manufacturing costs and longer production times.
Heavy-copper circuit boards can be designed to withstand the stresses of excessive currents and elevated temperatures, which can destroy ordinary PCBs in seconds. These boards have a higher tolerance capacity and are therefore used in demanding applications such as rail traction systems and solar power converters.
The current-carrying capacity of a heavy copper PCB is dependent on its Heavy Copper PCB Supplier copper weight, trace width, and the maximum temperature rise it can withstand. To determine the maximum current, PCB designers must gauge how much the board can carry and then calculate the copper thickness and trace width using a tool.
The substrate of a heavy-copper PCB is also critical. The material should have a low TCE to prevent cracks and layer separation, as well as a high Tg to resist the high mechanical stress of the plated holes. In addition, the material should have a low coefficient of expansion to accommodate changes in temperature.
Reliability
One of the most important factors for PCB design is reliability. It is crucial to avoid stress points, such as plated holes and border edges, in order to reduce the chance of damage or failure. This is important because these areas can cause short circuits and other issues that may compromise the reliability of the entire board. Another important factor is the ability to handle current levels. Heavy copper PCBs are capable of handling more current than standard PCBs, which makes them a better choice for high-power applications.
The metallurgy of a PCB is also important for its performance and reliability. It is essential to choose a suitable substrate material and etching technique to ensure that the copper layer is thick enough to provide a stable platform for your components. In addition, you should also consider the glass transition temperature of your substrate. It should be high enough to prevent cracks in the copper layer due to excessive current.
Heavy copper PCBs are used in a variety of high-end industries, including aerospace and military devices. These boards can handle a wide range of conditions, including extreme temperatures and humidity. In addition, they are often used in high-tech electronic products that require a higher level of reliability and anti-interference. These requirements are difficult to meet with conventional PCBs, which can become damaged over time.
Design
Heavy copper PCBs are used in power converters and planer transformers, as well as other high-current circuits. They have higher current carrying capacity and are more energy efficient than standard copper-clad boards. They also have better thermal distribution and dissipation. However, these features come at a cost. They are more expensive and take longer to fabricate. Therefore, they are not appropriate for all applications.
To design a heavy copper PCB, you must gauge the amount of current needed for your application and select the right thickness. This will affect the temperature rise, current capacity, and maximum current density. You can use a trace width calculator to determine the best design for your application. These tools can calculate the relationship between trace width, current capacity, and temperature rise.
Another factor to consider is the material of the substrate. FR-4 is a common choice, but other materials are available. Some have glass transition temperatures (Tg) higher than FR-4, which can help increase utilization and reduce the likelihood of layer separation.
The copper thickness and width of the PCB are also important factors to consider when designing a heavy copper PCB. A thinner copper will cause more voids in the etching process, which can be costly. Increasing the copper thickness can decrease this problem and make the etching process easier.
