Thick Copper PCBs

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A Complete Guide on Thick Copper Printed Circuit Board

The high development in electronics and telecommunication industry, the Thick Copper, printed circuit boards, are widely in use. Thick Copper means that the thickness of copper is more than the 140um (4 Oz).

This factor is essential when comparing the standard PCB weights 1-2 Oz (35um) to Thick Copper PCB. The features of Thick Copper PCBs are mainly required in the power electronic devices and central power system.

Thick Copper PCB Design Considerations

The width and copper weights are the crucial parameters for electrical engineers while designing a Thick Copper PCB. These two features determine the current-carrying capacity of the Thick Copper PCB. For PCB manufacturers, high-current is a challenge because their manageable load links to safety concerns.

Moreover, the solder mask process requires strict control during the process because the amount of copper thickness is greater than the substrate thickness.

Besides, the manufacturing process, such as pattern etching, drilling, and lamination process, also need to be carefully controlled during the manufacturing of Thick Copper finished PCBs. The Thick Copper PCBs are made with different copper weights on small footprints.

In PCB copper manufacturing, the structure has an essential role because it helps in reducing risk and avoids unnecessary cost, which results from complex PCB structures. Thick Copper finished PCB's offer lasting wiring solutions to fulfill the requirements of better thermal management systems.

They conduct optimal electricity and additional thermal dissipation. Allowable minimum weight, dimension, types of the components and materials, and spacing are the three design parameters that must be checked.

Thick Copper PCBs Fabrication

Smooth and frequent communication between electronic design and manufacturing engineers bring successful PCB fabrication. Design engineers must be aware of the manufacturer's detail such as capacity, trace, spacing, via diameter, and square foot size, etc. Besides, PCB type requirements have to be taken into consideration like power, thru-hole structure, and material.

For Thick Copper PCBs, the fabrication method is similar to standard FR4 PCB. Fabricating Thick Copper printed circuit boards involve etching and plating processes like high-speed plating and deviation etching. The main goal is to include a copper thickness in sidewalls and holes.

During the production process, when the printed circuit board is subject to several cycles, the plated holes may get weak. Ideally, the holes strengthen when Thick Copper is added. That is why in electrical circuits, it is preferable to choose extreme current and power applications.

It is possible to attach Thick Copper PCBs to the ordinary board seamlessly. Shortly, in the past, manufacturers tried to construct Thick Copper PCBs with the etching process only. Fabrication of few circuit boards underwent from scrap in this method because of over-etching margin and uneven edge lines.

To avoid this, later, advanced etching and plating techniques were applied to achieve optimal etching margin and straight edge. During Thick Copper PCB fabrication, assembling of cooling fins is of high significance.

The plating process thickens the thru-hole wall and plated through-wall in the Thick Copper PCB fabrication, and thermal conducting property on board surface is improved. Thick copper PCB advantages are:

  • 1. Shrinking layer count
  • 2. Reduction in impedance distribution
  • 3. Decreased manufacturing price
  • 4. Minimization of packaging

Edges of Thick Copper PCB

Let's go through quickly some of the main benefits of Thick Copper PCB:

  • 1.Easy Implementation: Even within the small spaces, they are easy to implement in the complex switches. Thick Copper PCBs removed the need for complex and bulky metal bars or wires.
  • 2.Thermal Distribution: The experts can work with the extreme thermal resistance because of the copper-plating of these PCBs anytime. Ideal thermal management and high-performance reliability are the actual reasons for their high demand.

In harsh environments like temperature fluctuations, Thick Copper finished PCB is to rely upon. For example, the mechanical resistance of PTH and contract points increases as well in ambient temperatures.

3.Thermal Dissipation: Overheating can fail any electrical system at any time. Here, Thick Copper circuit boards play their role. They help in avoiding possible overheating. This feature helps to maintain the temperature of the whole system easily to the desired levels. The circuit board dissipates the Thermal effectively hence, ensures optimal circuits performance.

  • 1.Exotic Material: Sometimes, the electronic component designing requires the utility of unusual materials. Thus, using a Thick Copper circuit board to protect and enhance such materials.
  • 2.High Current Conduction: In the electrical industry, Thick Copper printed circuit board help in extreme current conduction. The printed circuit boards link different boards together to make sure excessive current cannot cut impulsively. Thick Copper finished PCB's have the best present carrying capacity and ability.
  • 3.Mechanical Strength: The full mechanical strength of the Thick Copper weights circuit board is ideally good. This feature makes a durable and robust electrical system as a whole.
  • 4.Heat Sinks: Heavy board PCB provide the onboard heat sink, which is an essential aspect of electrical and electronic systems. On mosaic surfaces, it is easy to achieve reliable and effective heat sinks. The heat transferring method between layers reduces the cost.

Applications of Thick Copper PCB

Understanding the application requirement is essential before opting for the heavy printed circuit boards. It is not a new invention. They have been used in developing defense and military applications of weapon control systems. Thick Copper PCBs are commonly used in below-mentioned areas:

1. Military applications like pumping plants storage

2. Rail traction and signal and safety system applications in the automotive industry

3. With heavy mosaic layer, they are used as planar transformers

4. In pulse converters, they are very famous as they help in developing smaller transformers with the inductance of low winding leak

5. They are used as solar power converters in solar panel

6. Amplification system and torque control applications

7. Protection and overhead relays in electrical power systems

8. Cooling HVAC (High power) systems

9. UPS systems in the telecommunication industry

With the increase in PCB technology and complexity, electronic engineers need to concentrate on PCB design rules and manufacturing techniques. This way, the product can achieve the optimal balance between cost, performance requirement, and security. The benefits of features lead to minimum manufacturing risks.

Why Choose PCBONLINE Thick Copper PCB Board.