Fabricating Heavy Copper PCBs
Using thick copper in PCBs offers many advantages including the ability to carry higher current levels and enhanced efficiency with better heat dissipation. However, designing with heavy copper can be challenging for the fabricator, and there are some important design considerations to take into account.
A close working relationship between the designer and the fabricator is essential for success with heavy copper designs. The following tips will help you achieve a successful outcome:
High-Speed Plating
PCBs are critical components used in all types of electronics, from toys to industrial equipment. These circuit boards require high currents, which generate heat that heavy copper pcb can damage copper traces. Heavy copper clad board technology can reduce the risk of this, as it conducts heat away from sensitive temperature-sensitive areas. This helps ensure the longevity of the electronic components and the integrity of the board.
A heavy copper PCB is a printed circuit board with greater than 3 oz of copper in the outer and inner layers. It is mainly designed for power circuits and some high current applications. It can be designed for either single-sided or double-sided boards.
Historically, PCBs with heavy copper required specialized etching and plating processes to create the desired features. These procedures were typically based on etching thick copper-clad laminated substrates, which often resulted in uneven trace sidewalls and unacceptable undercutting. However, the latest plating and etching techniques have allowed PCBs to incorporate heavy copper with standard features, making them more cost-effective than ever before.
The key to creating a reliable heavy copper PCB is to choose the right thickness. The thickness must be sufficient to withstand the amount of current the circuit board is expected to carry. To determine this, a PCB designer must first estimate the maximum current and temperature rise that can be borne by the copper conductor. Then, the appropriate trace width can be determined by using a tool that calculates these parameters.
Deviation Etching
A standard PCB is made of copper traces and planes that are etched, then plated to add thickness. These are then laminated with an epoxy-based substrate, such as FR4. Heavy copper PCBs use a different fabrication method, and are fabricated using plating and engraving technologies that enable high-speed ink drilling and deviation engraving. These techniques are essential to the fabrication of a high-quality heavy copper PCB.
When current flows through a copper trace, it generates heat that must be dissipated in order to prevent circuit damage. The thicker material of a heavy copper PCB helps to dissipate heat quickly, which improves the efficiency and reliability of the circuit board. This is especially important in high-power applications, where the board needs to be able to handle large amounts of current.
PCBs containing 10 oz copper have an excellent electrical conductivity, which allows them to carry high currents without degradation of the board’s physical properties. They also have a higher dielectric constant, which makes them suitable for high-speed circuits. They are also a good choice for harsh environments, such as high temperature and intense moisture.
High Pressure Pressing
Traditionally, heavy copper circuit board features were formed entirely by etching thick copper clad laminated boards. This technique caused uneven trace sidewalls and unacceptable undercutting. However, advances in plating technology now allow heavy copper features to be formed with a combination of etching and plating, which produces straight sidewalls and negligible undercutting. In order to take advantage of these advantages, it is crucial that the fabricator and designer discuss manufacturing capabilities early in the design process.
For PCBs that contain thick copper, the areas that should not be soldered must be covered with a special material known as solder mask. Solder mask is a dry film that is photoimaged onto the PWB and developed to remove the unexposed area. It is important to choose a high-quality product, such as LPI (liquid photoimageable solder mask) for this purpose.
PCBs carry current through etched copper tracks, which can be modified to increase their current carrying capacity by increasing their width. Another way to enhance current carrying capacity is by using heavy or thick copper, which can withstand more shock and vibration. Heavy copper also conducts heat better, enhancing efficiency and performance.
Air Guide Grooves
Once the PCB layers have been pressed together, there is still some work to be done before the PCB can actually be used. The technician will have to remove the top press plate and pins and X-ray the board to locate the locations of the holes they need to drill. They will then use a computer-guided drill to make registration/guiding holes which will secure the layers to each other while they make the more specific holes on the actual circuit board.
Once these have been made, the PCB Heavy Copper PCB Supplier will be ready for mounting. However, it is important to find a manufacturer that understands the unique needs of heavy copper pcb in order to get the best possible product. Otherwise, you could end up with a product that is defective or does not meet your exact specifications.
For example, the manufacturer should be able to produce the PCB with multiple layers and large layout structures on both the inner and outer surfaces. It should also be able to provide an appropriate amount of heat dissipation and tensile strength for your application. In addition, the manufacturer should offer a wide variety of material options for your product and be UL and ISO accredited. Finally, the manufacturer should have an excellent customer service team that can answer any questions or concerns you may have.
