Heavy Copper Power PCB

PCBs with heavy copper circuitry have been used in military and aerospace industry for years but are gaining momentum as a technology of choice in industrial applications.

The core merits of Heavy Copper power PCB include current carrying capacity, thermal dissipation, and durability. Embedded copper method allows for large PCB-cross sections that are ideal for high current output and encourages good heat dissipation.

Heat Resistance

Heavy copper power PCBs feature superior heat resistance. This enables them to dissipate more current efficiently, increasing the overall capacity of the circuit board. In addition, they can handle a greater range of temperatures. Unlike standard circuit boards, heavy copper can easily disperse heat from the components and the surrounding atmosphere through thermal conduction and radiation. This helps to reduce the failure rate of the components.

As current passes through a trace, it generates excessive heat that inadvertently Heavy copper power PCB increases the resistance of the circuit. The transited heat then provides a power that dissipates into the environment through convection and conduction. The designer of a power PCB should calculate the maximum current that can be carried by the trace before it exceeds the acceptable temperature rise of about 30 degrees Celsius.

A heavy-copper PCB can also carry high currents with standard features on a single circuit board. However, it is important for the designer and fabricator to discuss manufacturing tolerances and abilities prior to the final design. This ensures that the copper and substrate can withstand the stress of a high current without causing layer separation or cracks.

PCB manufacturers must use specialized etching techniques to create straight edges and good margins on heavy-copper circuit boards. This is because conventional etching methods can cause over-etching and uneven edges. They must also use plating to increase the thickness of the plated holes and via sidewalls.

Thermal Conductivity

Heavy copper power PCBs are able to tolerate frequent exposure to excessive current, elevated temperatures and recurring thermal cycling that can destroy a regular circuit board within seconds. This enables these circuit boards to be used in rough situations such as defense and aerospace industry products, power adapters/alternators, and thermal regulators.

This is because they have excellent thermal conductivity. The copper trace on a heavy PCB absorbs the excess heat and dissipates it through convection and conduction. This enables the trace to cool down faster than it can heat up. In fact, the maximum current a copper circuit can carry depends on how much temperature rise it can withstand. This can be estimated using a tool that calculates three parameters: trace width, current capacity, and temperature rise.

In addition, the increased copper thickness on a heavy power PCB increases its current-carrying capability and allows it to be manufactured with a lower layer count. This enables designers to incorporate control circuits with high-current capability and achieve a compact board design.

A heavy copper PCB also offers improved performance when it comes to plated-through holes and vias. The higher copper thickness helps to ensure that these features are insulated from each other. In turn, this reduces the chance of shorts and other electrical defects. In addition, these thick copper features help to improve heat dissipation and prevent overheating.

Current Capacity

When current passes through a copper trace it causes excessive heat, which is transferred to the surrounding air through conduction and convection. This heat dissipates the power in the atmosphere to prevent the circuit from overheating. It is important to know how much current a copper trace can carry without becoming overheated. This is because the excess current may cause a short-circuiting of the circuit or even burn out the copper layer.

Heavy copper PCBs can provide the additional strength required to withstand high current loads. They are used in a variety of applications, from complex switches to power converters. These thicker copper layers help to improve the efficiency of the circuit by controlling the temperature more effectively and delivering more consistent performance. Copper also has an outstanding thermal conductivity, which allows it to dissipate heat faster. This makes it easier for the devices to run stably for an extended period of time.

Circuit board manufacturers and designers can choose from a variety of dielectric materials, from standard FR-4 to high-temperature polyimide. However, if a product requires a higher operating temperature or is exposed to extreme environments, will the standard 1 oz/ft2 of copper on the circuit dashes and plated vias be able to withstand these conditions? To answer this question, the circuit PCB industry has developed a test method to determine the thermal integrity of a finished board.

Thermal Dissipation

In printed circuit boards, thermal dissipation is essential. Due to the high current and extreme temperature requirements, power components generate I2R losses in the form of heat, which needs to be conducted away from the components or else they might overheat. Heavy copper PCBs are able to conduct heat away from the critical components, thus preventing overheating and prolonging their lifespans.

However, it is crucial to consider the thickness of your copper layer and the track/gap spacing when choosing a power PCB for your application. It is also important to choose a reliable Heavy Copper Power PCB Supplier PCB manufacturer with the capacity to produce your product according to your specifications. This way, you can rest assured that your heavy copper power PCB will deliver a high-quality result every time.

The reason that thicker copper is preferable to thinner copper is that the wider PCB cross-section allows higher current outputs and encourages effective thermal dissipation. Additionally, it allows the PCB to accommodate larger power components without any overlapping tracks. This helps reduce the size and weight of the power PCB while maintaining its performance.

The heavy copper construction process also eliminates the need for external heat sinks and allows the primary and secondary winding of a transformer to be printed directly on the PCB. These features help improve the quality of the power PCB and make it more durable in the long run. This makes it ideal for applications such as industrial, automotive, and military controls.