Benefits of Heavy Copper PCB
PCBs that use heavy copper conduct electricity more efficiently than standard PCBs. This technology is gaining popularity for applications like power converters and planar transformers.
When designing a heavy copper circuit board, you must consider the thickness of each layer. The design of these circuits requires a close relationship with the fabricator to ensure the resin fill can accommodate the copper.
Cost
PCBs are essential components in many electronic devices, equipment, and appliances. They provide a compact and reliable path for current to flow through the circuit. However, certain products require heavy currents that standard PCBs cannot handle. In such cases, heavy copper circuit boards are required. These high-quality PCBs are in great demand due to their reliability and thermal control.
To manufacture a heavy copper PCB, manufacturers use specialized etching and plating techniques. These techniques help them achieve straight trace sidewalls and negligible undercutting, which are crucial for achieving good performance. Previously, these features were created by completely etching in-depth laminated heavy copper pcb clad copper material, but advances in plating technology have made it possible to create them with a combination of coating and etching.
This method also helps the circuit board withstand higher temperatures. This makes it ideal for automotive applications, such as power distribution units and electric motors. It also allows the circuit to be used in demanding environments, such as the aerospace industry.
Heavy copper pcbs are more expensive to fabricate than standard FR-4 PCBs, but they offer several benefits, including increased current capacity and improved thermal performance. To determine whether a heavy copper PCB is appropriate for your application, consider the following factors:
Temperature
Printed circuit boards (PCBs) are the building blocks of modern electronics, connecting components and transmitting electrical signals. They are also critical to the operation of the devices they control, and can fail in certain situations. These issues are often caused by thermal stress or high currents. Fortunately, there are ways to improve the temperature of PCBs and eliminate these problems. One way is to use heavy copper. This type of copper has a lower melting point, which allows the board to withstand higher currents and temperatures without damage.
Another benefit of heavy copper is its ability to withstand recurring thermal cycles, which can destroy regular circuit boards in seconds. This advantage is especially important in military and aerospace applications, where PCBs may be subjected to constant exposure to high currents and elevated temperatures. Heavy copper can withstand these conditions without damage, making it ideal for defense industry products and power adapters/alternators.
In addition to providing greater current carrying capacity, heavy copper can also improve performance and efficiency. The extra thickness of the copper layer allows for larger PCB cross-sections, which can facilitate heat dissipation. This can reduce the amount of thermal resistance, which results in increased conductivity and better utilization of the device.
Despite these benefits, it is still essential to consider the fabrication process when designing a circuit board with heavy copper. These types of PCBs have a different reflow soldering temperature than other PCBs, so it is important to consult a manufacturer early in the design process.
Heat Dissipation
Heavy copper PCBs are used in a wide range of applications, including EV-chargers, high current systems and power storage devices. These thicker copper layers provide better heat dissipation and help prevent overheating in the circuit boards. This helps improve device performance and extends the life of the components on the board.
As current passes through a copper trace, it causes a local heat transition that generates power that is dissipated by conduction and convection. This heat will limit the amount of current that a circuit can carry. The circuit designer should use a trace width calculator to determine the maximum current capacity of a trace.
The thickness of a PCB’s copper layer is one of the most important factors in its current carrying capacity. The higher the copper thickness, the more current it can carry. The PCB designer should select a copper weight and trace width that will maximize the current-carrying capability of the circuit board.
The substrate material of a heavy copper PCB should have a low thermal expansion coefficient (TCE) to avoid cracking and layer separation. It also needs a high glass transition temperature (Tg) to withstand the mechanical stress of high current flow. Finally, the circuit board should have a good mechanical strength to ensure that it can resist vibrations and other external forces.
Safety
There are many benefits of heavy copper pcb, including the ability to handle high currents without overheating. This feature makes them perfect for use in electronic devices that require higher frequency and speed. In addition, they have high thermal conductivity, which allows them to pull heat away from the components in the device. This results in a smaller failure rate and lower operating costs.
Heavy copper clad PCBs are also more durable than standard circuit boards. They can withstand extreme temperature and humidity conditions, which are common in the aerospace industry. This makes them ideal for avionics systems, satellite communication systems, and power adapters and alternators. They can also withstand repeated exposure to high current and elevated temperatures, which would destroy a standard circuit board in seconds.
The copper layers in a heavy copper clad PCB are thicker than those on traditional circuit boards, and the plating process is more precise. This means that the copper can be etched at a lower temperature and with less stress on the substrate. This results Heavy Copper PCB Supplier in better thermal distribution and increased mechanical strength at the plated through holes and connector sites.
PCBs with heavy copper can be made using a variety of methods. These include routing, punching, and V-cutting. They can be finished with an immersion gold or HASL coating. The copper thickness can be adjusted to match the requirements of the customer, and they can be cut down to size if needed.
