Factors to Consider in Heavy Copper PCB Design

pcb design model When designing Heavy Copper PCBs, there are several factors to consider, including:

Copper Thickness: The thickness of the copper layers in Heavy Copper PCBs should be carefully chosen based on the specific application requirements. Trace Width and Spacing: The trace width and spacing should be designed to meet the required current carrying capacity without causing excessive heat generation.

Thermal Management: The design should include adequate thermal management techniques to ensure efficient heat dissipation.

What is Heavy Copper PCB?

Typically, most PCBs are manufactured using copper thicknesses ranging from 1oz to 3oz.However,a heavy copper PCB refers to a PCB where 3oz or greater copper is used on all layers of the board (both inner and outer layers).

Heavy copper PCB is a printed circuit board used for applications that carry high currents. Copper is generally a good conductor of electricity as well as heat. Heavy copper PCBs are printed circuit boards with thicker copper thickness in the inner or outer layers, usually ranging from 3 oz (105um) to 15 oz (420 um) copper thickness.

The cross-section of the heavy copper PCB is shown below. A clear-cut view of isolation layers and thickness of copper is shown. In this type of heavy copper PCB, the isolation layer is kept thick to provide electrical isolation and mechanical reliability.

Benefits of Heavy Copper PCBs

1. High Current Capability One of the most significant benefits of Heavy Copper PCBs is their ability to handle high currents going through the copper layers. Thicker copper layers allow Heavy Copper PCBs to carry more current without overheating or decreasing overall board characteristics. This makes them ideal for use in power electronics, where high currents are often required. Heavy Copper PCBs can handle currents of larger then 30 amps, depending on the thickness of the copper layers, as well as board stackup.

2. Increased Thermal Management Heat dissipation is a critical factor in the performance and reliability of electronic devices. Heavy Copper PCBs are designed to provide superior thermal performances, thanks to their thicker copper layers. Thick copper layers provide large thermal mass that helps with dissipating heat away from the components and reducing the risk of thermal damage. This makes Heavy Copper PCBs ideal for use in high-power applications, where heat dissipation is a significant problem.

3. Enhanced Durability Another benefit of Heavy Copper PCBs is their enhanced durability. The thicker copper layers make the board more robust and less susceptible to damage from mechanical stress or thermal cycling. Heavy Copper PCBs also have a longer lifespan than standard PCBs, making them ideal for use in applications where reliability is critical.

Applications of Heavy Copper PCB

Heavy copper PCBs are becoming more and more popular due to their wide application in the following fields:

Military: Weapons control, radar, and monitoring systems.

Automotive industries: Rail track system and signal transmission system.

Power distribution: Excitation systems for power regulators, power grid switching systems, high power rectifiers, and overload relays.

Transportation: Power converters for railway systems, power line monitors, traction converters.

Industrial controls: Safety and signal systems, welding equipment, protection relays, surge protectors.

Renewable Systems: Power converters, energy storage, power grid back-up, hydroelectric power plants control panels.

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