Heavy Copper Power PCB
Heavy copper power PCBs have thicker copper layers than standard PCBs. This gives them high current capacity and thermal management capabilities.
The copper trace in a finished heavy copper circuit board carries current and dissipates power loss according to the formula below. Heat flows to the surrounding components and then to the air by convection and conduction.
Heavy copper power PCBs are used in applications requiring high current and voltage. These circuit boards have a higher copper thickness compared to standard circuit boards and can withstand higher temperatures. They also have the ability to transfer heat through the entire board, reducing the risk of failure due to thermal stress. These factors make them ideal for use in EV-chargers and other high-current devices.
This increased thickness enables a higher current-carrying capacity and a lower layer count. It also allows for a better distribution of power to the components on the board. Additionally, it enables a reduction in the overall size of the product. Heavy copper plated vias provide additional heat transfer, minimizing the skin effect and improving current density.
A PCB’s traces must conduct the highest amount of current possible to function properly. However, this can create significant amounts of heat. This heat must be dissipated in order to keep the electronics cool and prevent premature failure. A heavy copper circuit board can conduct this heat away from the important components, ensuring their longevity.
This increased copper thickness is achieved by using special plating and etching techniques. These techniques allow the fabricator to increase copper thickness in plated holes and via sidewalls. This allows the combination of heavy copper and standard features on a single PCB, which can reduce layers, improve current distribution and lead to cost savings.
High Current Capacity
Heavy copper power PCBs are designed to handle higher current levels compared to traditional PCBs. This is accomplished by using thicker copper layers that reduce resistance in the conductive path, allowing more current to flow through the board. They also offer better mechanical strength at stress points, which helps prevent bending and damage.
A high-power circuit board’s current carrying capacity is proportional to its copper thickness, width and the maximum temperature rise it can withstand. To determine this, designers use a trace width calculator, which calculates the three parameters and helps them choose the right one for their project. This tool also helps them select the best material for their high-power Heavy copper power PCB circuits, ensuring it will be strong enough to carry large current outputs without melting or losing its shape.
Another way to increase a circuit board’s current carrying capacity is to utilize square polygon pours instead of traces, which will allow the copper to have a larger cross-section and improve the thermal distribution. This will help reduce DC power loss and make the board more reliable. Moreover, this method will enable engineers to create complex switches within the same space as standard circuit boards. It will also enable them to add features like cooling channels and heat sinks without affecting the design of the circuit board. Moreover, it will help eliminate the need for overlapping layers, which can increase thermal strains and lead to failures.
High Temperature Resistance
Heavy copper power PCBs are designed to withstand high current levels and extreme environmental conditions. They can handle recurrent thermal cycles and are able to dissipate heat efficiently. They also provide excellent mechanical strength at connector sites and plated through holes. These features make them ideal for use in the automotive industry, power supplies, and welding equipment.
In order to achieve this, they have a higher copper thickness than regular printed circuit boards. This is typically 3oz or more. In addition, the substrate material must be able to withstand high currents. This is because the differences in the coefficients of thermal expansion between the copper and the substrate create a driving force for crack nucleation, propagation, and failure of the circuit board.
To avoid this, PCB manufacturers and designers must use a special copper etching and plating process. This allows them to achieve straight edges and even trace sidewalls. It also provides the necessary flexibility to accommodate the increased thickness of the copper wires.
However, these techniques must be used carefully when designing heavy copper circuits. The designer must understand the maximum current-carrying capacity and how it relates to the thickness of the copper, the substrate material, and the plated hole Heavy Copper Power PCB Supplier sidewalls. This will help them determine the appropriate copper weight and etching process, as well as the temperature rise that the circuit can withstand.
Heavy copper power PCBs have a higher durability than standard circuit boards and can withstand harsh environments. They are ideal for applications in which high currents are needed and can dissipate heat efficiently. They are also more resistant to moisture, cold, and corrosion. This makes them ideal for use in automotive, military, and aerospace grade products.
Due to their ability to conduct higher currents, heavy copper PCBs have found growing usage in the industrial sector, especially in complex switches that need to fit into a compact space. This is made possible by the addition of hefty copper layers on the interior of the board, which can handle a larger load and ensure good thermal distribution.
The design of a heavy copper PCB requires careful planning to ensure that it can support the required load. This involves gauging the amount of current that will be passing through the conductor, as well as determining the maximum temperature rise the board can withstand. To determine these factors, a designer can use a trace width calculator, which considers three key parameters: copper thickness, current capacity, and temperature rise.
Despite their high price tag, the durable properties of heavy copper power PCBs make them an excellent choice for industrial and high-end consumer electronics. They are especially useful for high-powered devices, such as trains and motor controllers, which need to be able to withstand large current loads and extreme temperatures. In addition, they are more resilient to corrosion and moisture than other types of circuit boards, making them a safe choice for use in harsh environments.