Heavy Copper PCB
The traces on heavy copper PCBs are thicker, which increases their current carrying capacity. This allows the board to withstand more current and prevents damage from excess heat.
However, it is important to find a manufacturer that has the experience and quality standards needed for manufacturing heavy copper PCBs. This will ensure that the boards meet your specific needs.
Cost
A heavy copper PCB has a much higher current carrying capacity than standard PCBs. This makes it suitable for applications that require a large amount of current, such as power systems and electric vehicles. It also has the ability to dissipate heat effectively.
Heavy copper PCBs are made with different inner layers that are bonded together using prepreg as the insulating layer. The copper foil appears thicker than on a standard printed circuit board, and the various parts of the board can be connected through vias. This makes the circuit board more rigid and allows it to support more complex components.
The thickness of the copper used in a heavy copper PCB is usually between 3 high speed pcb and 10 ounces. This is significantly more than the 1 ounce of copper that is typically used in standard PCBs. The additional copper increases the cost of a PCB, which is why manufacturers should keep this in mind when developing their designs.
To reduce the cost of a heavy copper PCB, it is important to design the copper traces and subdivisions correctly. In addition, it is essential to use advanced etching techniques that can provide consistent results. In addition, the trace width should be as short as possible to avoid excessive power loss and heat generation. For larger currents, it is recommended to use solderable copper bus bars instead of copper traces.
Applications
Heavy copper PCBs are used in a variety of applications. They can support high frequencies to excessive current, elevated temperatures, and recurrent thermal cycling that can ruin a regular circuit board in seconds. This makes them a reliable wiring platform that is in great demand in the computer, automobile, military, and industrial control industries. These boards are fabricated using a combination of plating and etching processes. During the process, copper thickness is added to via sidewalls and plated holes, which helps strengthen them. This allows for a higher current capacity and lower layer count. It also increases the elongation performance of the PCB.
A key advantage of heavy copper PCBs is their ability to dissipate heat. This is especially important for large power circuits that require a lot of current. Adding copper plating to through holes and matching them with heat sinks can help reduce the amount of heat produced by the board. It can also increase the power distribution capability of the board.
A good way to gauge the current-carrying capabilities of a PCB is by using a trace width calculator. These calculators determine the maximum current a circuit can carry by considering three different parameters: current, temperature increment, and width of the conductor. These tools are available online and can be easily used by PCB designers.
Design
The design of heavy copper pcbs requires specialized plating and etching techniques to make them durable. This includes the use of differential etching and high-speed/step plating techniques. These techniques help to create powerful copper features with straight sidewalls and low undercutting. This helps to prevent heat buildup and oxidation in the traces. It also increases current-carrying capacity. In addition, the technique allows for better control of the thickness of a trace.
PCBs with heavy copper circuitry are capable of handling higher current levels and more complex switches in a limited space. They are often used in electronic devices such as power converters, planar transformers, and power distribution units. They can also support a wide variety of applications, including military and aerospace products.
Heavy copper clad PCBs have a greater tolerance capacity than regular circuit boards, and can handle excessive currents and recurrent thermal cycles. This makes them an ideal choice for use in rugged environments such as power converters and industrial controls.
The design of a heavy copper PCB requires careful consideration of the substrate material and the relationship between copper and the underlying laminate. This ensures that the board will not crack or break during the manufacturing process. Additionally, the choice of a suitable substrate will affect the board’s High-Speed PCB Supplier ability to conduct heat and to dissipate it effectively. The proper substrate material can also help to reduce the resistance of copper traces and improve their performance.
Manufacturing
The manufacturing process for heavy copper pcb is complex, and requires specialized etching and plating. It also involves using different copper thicknesses, depending on the design requirements. These factors make it more expensive than standard PCBs. In addition, it takes longer to produce heavy copper PCBs. However, the benefits of these PCBs are worth the extra cost.
When a printed circuit board is made with heavy copper, its current carrying capacity increases because the copper thickness is greater than the typical thickness of standard copper. In turn, this enables the board to carry more currents without changing its width. The increased current-carrying capability is important for high-power circuits, such as power converters and planer transformers. In addition, the copper thickness helps achieve better thermal distribution and implement complex switches in a compact space.
In the design process, it’s critical to take into account the copper weight, plating thickness and substrate material when determining the current-carrying capacity of a PCB. The substrate material should have a low coefficient of expansion to avoid cracking and stress on the copper. It should also have a high glass transition temperature to withstand the high mechanical stress of plated holes. It should also be able to absorb the excess heat generated by the copper traces. If you’re interested in using heavy copper in your next project, contact a PCB manufacturer to discuss the options and costs.
