Heavy Copper is a kind of copper foil with a thickness of 3 oz or more. It is commonly used in power circuits and high-current supply applications. Its properties also include increased mechanical strength and thermal conductivity. This material is commonly used in power circuits for automotive applications.
Increased current carrying capacity
The increased current carrying capacity of heavy copper PCB allows it to be used in various electronic devices. It can sustain high currents and high temperatures. It can also handle recurrent thermal cycles. Because of its enhanced performance, heavy copper PCB is used in various applications, including computers, automobiles, and military devices.
PCB fabrication shops usually buy copper sheets in fixed weights and thicknesses. However, engineers can change these parameters to improve signal flow and integrity. The IPC-2152 standard specifies trace parameters, which include copper weight, trace width, and trace length, depending on the electrical/thermal properties of the board.
Heavy copper circuit boards can be manufactured similarly to light copper PCBs but require special etching and plating processes. In the past, heavy copper circuit boards were formed by etching a thick copper-clad laminated board material. This led to uneven sidewalls and unacceptable undercutting. However, more recent techniques now allow for the combination of etching and plating to produce straight sidewalls and minimal undercutting.
Improved mechanical strength
The increased thickness of heavy copper PCB allows high currents to be safely conducted while also improving its thermal performance. A typical high-current PCB has a copper thickness of 0.5 to 3 oz per square foot. However, extreme copper PCBs may have as much as 200 oz per square foot of copper.
This increased thickness also reduces the loss associated with the boards’ thermal properties. This leads to lower board temperature due to thermal stress. In addition, the copper plating eliminates the need for load-sharing and reduces failures related to thermal stress. Finally, it also provides a cooler running PCB.
The added thickness of heavy copper PCB is achieved through plating or etching processes. These methods add copper to the board sidewalls and through holes. The result is a more durable board with increased electrical performance. Furthermore, heavy copper PCBs dissipate heat generated by heavy currents, which is essential for preventing overheating.
Increased thermal conductivity
Heavy copper PCBs are a good choice for high-current-output circuits. These boards can handle higher levels of thermal conductivity than other materials. As a result, they are more resistant to oxidation and corrosion and can handle higher heat levels. However, they require a higher manufacturing temperature and must be laminated properly to prevent pads from being detached.
This PCB is also used for power modules and automotive electronic components. While some of its applications are the same as conventional PCBs, there are also many newer uses. For instance, it can be used in satellite communications and mobile phones.
In addition, it can be used in other high-tech fields like aerospace.
When designing PCBs with heavy copper, it is important to consider the thickness of the copper layers. Because heavy copper PCBs require substantial plating thicknesses, they require different pad sizes and trace separations. This is why it is important to include your board fabricator early in the design process.
