Benefits of Heavy Copper Power PCB
Heavy copper power PCB has long been used in military and aerospace applications, but now it is becoming increasingly popular in other industries. These specialized circuit boards can handle higher current flows and provide better thermal management capabilities.
The thicker copper traces generate more heat, but they also conduct more heat away from the components, which reduces failure rates. This makes them ideal for high-power applications.
High Temperature Tolerance
The primary benefit of Heavy copper power PCBs is their ability to tolerate excessive current and elevated temperatures. This enables them to function in rough environments such as defense and aerospace industry products, power adapters/alternators, thermal regulators and more. In addition, these circuit boards also have excellent weather resistance. This is because they are made from special dielectric materials that improve the overall weather resistance of the product.
In order to determine how much current a heavy copper board is capable of carrying, electronic design engineers must gauge the amount of current required and then calculate the copper thickness and width along with the maximum temperature rise it can withstand. These parameters can be easily determined with a current-carrying capacity calculator.
A key feature of Heavy copper circuits is their ability to withstand higher levels of temperature stress due to their high conductivity. This makes them ideal for power transmission and engine systems in electric vehicles and cars. In addition, they can handle rapid changes in temperature, ranging from as low as -40C to as high as 165C.
Due to the higher conductivity of heavy copper, it is necessary to use special dielectric materials that have a high tolerance and manufacturing capability. This is because they must be able to cope with temperature fluctuations and expansion. In addition, they should have a similar CTE to copper layers in the same stack, otherwise they will expand at different rates and lead to serious problems.
High Current Capacity
Heavy copper PCBs have a high current-carrying capacity. They can withstand higher levels of currents than standard PCBs and dissipate heat much better, making them ideal for power electronics applications. They’re also used in rail traction systems to prevent power Heavy copper power PCB failures. They’re also used in solar energy conversion units to provide a stable power supply and improve efficiency.
This technology has various variants, but most of them feature embedded copper parts that protrude from the surface to contact SMDs or other power components. The contacts on these copper parts are shaped like plugs or modules and can be pressed into place. This helps to eliminate the risk of solder penetration in the layers below. Moreover, it also makes it easier for the board to connect with external wires and modules.
In addition, these copper parts are plated with different materials to improve thermal management. These layers are designed to conduct heat away from the components and into the surrounding substrate material. In this way, the PCB can reduce the chances of overheating, which will lead to a decrease in performance.
Another advantage of this technology is that it’s easier to fabricate than traditional circuit boards. These copper parts are manufactured using etching, milling, or punching methods, and are then pressed with prepregs and other layers to make the finished circuit board. They also have a lower layer count, which allows them to be thinner and lighter than other types of PCBs. This means they’re cheaper to ship and handle.
High Resistance To Thermal Stress
Heavy copper power PCBs have high resistance to thermal stress which makes them suitable for use in a variety of environments and applications. The resistance to thermal stress helps to increase the life of the board and reduce downtime due to failure. The resistance to thermal stress is determined by the thickness of the copper and the substrate material. The plated through holes are also tested for the ability to resist thermal shock. The test involves circulating a chain of 32 serial plated through holes on the PCB for several cycles and the situation of each is checked after the circulation to determine how much of a strain it can tolerate.
The current passing through the copper trace heats it up and the local heat transition generates power that dissipates into the environment through conduction and convection. This dissipation process can reduce body effects and improve the current-carrying capacity of the trace. A thumb rule in the industry is that a copper trace can sustain a maximum of 30 degrees Celsius rise before the resistance starts to increase significantly.
Circuit board producers and engineers can select from a wide range of dielectric supplies, from standard FR4 (working temperature 130degC) to high-temperature polyimide (working temp. 250degC). A high-temperature or extreme environment may demand an exotic material, but if the circuit traces and plated vias are ordinary 1 oz/ft2, will they continue to endure the harsh conditions? The PCB industry has developed a tried and tested way of defining the thermal reliability of a completed heavy copper PCB.
High Heat Dissipation
As the current flows through the wires, it will generate heat and transfer that heat to the surrounding materials. This is why high-performance PCBs have thicker copper layers to dissipate the heat efficiently. This is particularly true for heavy copper power PCBs which are designed to run large electrical devices and appliances that require more current to function properly.
Another key benefit of heavy copper circuit boards is their increased endurance to thermal strain. This allows them to carry more electricity with less heat than standard copper PCBs. In addition, they can withstand the stresses of harsh environments such as high humidity and shock or vibration. This is important for the aerospace industry where reliability and safety are paramount.
Heavy copper PCBs can also handle more electricity because they have higher cross-sectional areas. This means that the current carrying capacity is Heavy Copper Power PCB Supplier proportional to the thickness of the copper trace, and thus larger circuits can be built.
For these reasons, heavy copper power PCBs are the preferred choice for demanding electronic applications. They are used in a wide variety of devices, including welding equipment, solar cell manufacturing processes, medical, automotive and military weapon controls. However, it is important to select a reputable manufacturer for heavy copper printed circuit boards. A poor quality product can damage the appliance or device and cause it to malfunction.