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Heavy Copper Design Methodologies


Description: Highlights design methodology of Heavy Copper Design, Heavy Voltage Design and Metal Core design on PCB used for specialized application in industry. This design technique is a part of intensive research done by some PCB Industry Veterans, which is not patented yet, but is used when required. Th


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Highlights design methodology of Heavy Copper Design, Heavy Voltage Design and Metal Core design on PCB used for specialized application in industry. This design technique is a part of intensive research done by some PCB Industry Veterans, which is not patented yet, but is used when required.

The topics Covered under this course are:

  • Heavy Copper Design
  • High Voltage Design
  • Metal Core Design

Heavy Copper Design

A heavy copper circuit is manufactured with copper weights between 4-oz/ft2 to 20-oz/ft2.  Copper weights above 20-oz/ft2 and up to 200-oz/ft2 are also possible and are referred to as extreme copper.  The construction of a heavy copper circuit endows a board with benefits such as:

  • Increased endurance to thermal strains
  • Increased current carrying capacity
  • Increased mechanical strength at connector sites and in PTH holes
  • Exotic materials used to their full potential (i.e., high temperature) without circuit failure
  • Reduced product size by incorporating multiple copper weights on the same layer of circuitry
  • Heavy copper plated vias carry higher current through the board and help to transfer heat to an external heat sink
  • On-board heat sinks directly plated onto the board surface using up to 120-oz copper planes
  • On-board high-power-density planar transformers

The ability to withstand high-level vibrations, such as those encountered on aircraft and space shuttles, makes heavy copper PCB technology an important advancement in field of PCB designing, and offers scope for career growth.

High Voltage PCB Design

For circuits expected to work in particle colliders, high altitude planes and outer space, the material specifications used to manufacture the PCB are different from those used for the conventional PCBs.  At such high voltages, strong electric fields, arc overs, and corona can cause significant damage to the material and its insulating properties, and blow up the circuit. Considering these possibilities, design high voltage PCBs and ensuring they give a reliable performance requires certain finesse in designing such PCBs and a sound knowledge of different manufacturing materials. 

Metal Core PCB Design

Metal Core PCBs dissipate heat and provide a much lower thermal resistance, in comparison to conventional PCBs, making them suitable for high power LED applications. Knowledge of the designing and fabrication of such PCBs is a feather in the cap for PCB designers.

 

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After 10 years of experience in pcb design fiel Heavy Copper Design methologies was unknown before I read your Tutorial - thanks for all good effort

- Ridhima Shrivastva

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