Benefits of Thick Copper PCBs

In today’s world of high power electronics PCBs act as the nerve centre for interconnecting numerous electronic components, enabling them to flow smoothly and effectively. But these modern electronic devices also require efficient power management and thermal dissipation. This is why thick copper PCBs are becoming increasingly popular, especially in the aerospace, defence and industrial automation industries.

thick copper pcb have a much higher current carrying capacity and superior heat dissipation, allowing them to efficiently manage the distribution of power. This is essential in power-intensive applications, where overheating and voltage drops can damage circuitry and compromise performance. The thicker copper plating on a heavy copper PCB also allows for better signal integrity, as it minimizes impedance mismatches and improves the quality of the conductive paths between different layers.

When designing a PCB, engineers use a CAD (Computer Aided Design) software program to specify the required layers and placement of all the components. Then, the base material for the board is prepared, typically a type of fiberglass like FR4. Holes are then drilled through the layers, and they are coated with copper to create the necessary connections between all the components on the board. These plated holes are known as vias, and they can be any size and shape, depending on the PCB’s design.

Thermal Benefits of Thick Copper PCBs

Using heavy copper in vias and plated through holes helps to reduce the risk of thermal stress failures that can occur as a result of vibration or mechanical shock, especially in harsh environments. This is because the additional copper plating in these areas increases the thermal conductivity of the hole, allowing it to remove more heat from the surrounding copper surface. This dramatically reduces the risk of thermal stress failure in these critical components.

A PCB’s ability to remove heat from the traces is determined by its copper plating thickness, the amount of surface area it has, and how it is stitched together. Increasing the copper plating thickness will increase its ability to remove heat from the board, as will adding more copper planes that are stitched together with through-holes. However, it is important to ensure that there is adequate space between the component and the copper planes to allow for proper airflow around the component and help with heat dissipation.

Thick copper PCBs, also known as heavy copper PCBs, represent a robust solution for applications demanding high current carrying capacity, better thermal management, and increased durability. Unlike standard PCBs, which typically feature copper thicknesses in the range of 1-3 ounces per square foot, thick copper PCBs boast copper layers exceeding 3 ounces per square foot, often reaching up to 20 ounces or more.

Another factor that contributes to the thermal performance of a PCB is the thickness of the annular ring surrounding the via holes. This ring should be at least 0.15 mm (6 mil) thick to maintain electrical connectivity and prevent copper cracking during thermal cycling. In addition, the diameter of the through-holes should be matched to the copper thickness to optimize signal transmission and allow for adequate heat dissipation.