Heavy Copper PCB
| P/N: S4I1 8663A0. | Layer Count: 4L | Min Line W/S: 8/8mil |
| Material:FR-4 Tg 135°C | Cu Thickness: 2/2oz | Min PTH: 0.45mm |
| Board Thickness: 1. 7mm | Surface: ENIG | Application:Industry Control |
| Soldermask Color: Green | Board Size: 273.05mmX158.75mm(1-up) | |
| Others: Impedance Control | ||
Product Features
Advantages of Heavy Copper PCB
Compared to conventional printed circuit boards, a PCB with heavy copper traces offers several advantages.
A Simple & Strong Structure
When integrated into the PCB, high current circuits allow designers to achieve higher density and reduce the layer count. This also maintains the relatively steady but not complex structure of the PCB.Reduce fault status.
Reduces Failure State
Complex printed circuit boards with high current requirements generate more heat. Copper has high heat-conducting abilities and helps to conduct heat away from vital temperature sensitive components.That's why heavy copper is chosen for the board that needs heat dissipation.
Lower Production Costs
Although copper is expensive, rather than use copper cables, using PCBs with heavy copper results in an overall lowering of production costs.The price is relatively cost-effective.
Heavy Copper PCB Manufacturing Capabilities
Victory PCB is a professional pcb manufacturer that can produce high-quality heavy copper PCB products. Check our PCB manufacturing capabilities in the following table.
Fabricating Heavy Copper PCBs
Products application
Some power electronics device require heavy copper PCB to carry larger current and voltage. They are heavy Copper and EXTREME Copper Printed Circuit Boards.
Heavy copper circuit is manufactured with surface copper thickness from 3Oz to 20Oz.
During design the heavy copper pcb, the engineers need to leave enough space between tracks and width to be convenient for production.
Application:
- Power module
- Battery Charger
- medical treatment
- Protection Relays
- welding equipment
- Industrial control
- Automotive electronic components
- high-tech product
- Home appliances
Industry information
Heavy copper is often used in high energy (or high current) printed circuit boards, specifically power electronic equipment and power supply equipment.
Quality Control of Heavy Copper PCB
- Accurately calculate the electroplating area and refer to the influence of the actual production process on the current, correctly determine the required value of the current, grasp the change of the current in the electroplating process, and ensure the stability of the electroplating process parameters;
- Before copper plating, firstly use the debugging board to test the plating solution and make it active；
- Determine the direction of the total current and then determine the order of hanging the boards. In principle, it should be from far to near; Ensure uniformity of current distribution on any surface
- In order to ensure the uniformity of the coating in the hole and the consistency of the coating thickness, in addition to the technical measures of stirring and filtering, pulse current is also required;
- Regularly monitor the current changes during the electroplating process to ensure the reliability and stability of the current value;
- Check if the copper coating thickness of the hole meets the technical requirements
Copper plating process
In the process of heavy copper electroplating, it is necessary to regularly monitor process parameters, often resulting in unnecessary losses due to subjective and objective reasons. In order to do a good job in the heavy copper electroplating process, the following aspects must be achieved
- Add a certain value based on the area value calculated by the computer and the empirical constant accumulated in actual production;
- According to the calculated current value, in order to ensure the integrity of the coating in the hole, a certain value, namely impact current, needs to be added to the original current value, and then restored to the original value in a short period of time
- After 5 minutes of electroplating on the circuit board, remove the substrate and observe whether the copper layer on the surface and inner wall of the hole is intact. It's best that all the holes have a metallic luster.
Welcome to send us RFQs about heavy copper PCB.
What is a Heavy Copper PCB?
A Heavy Copper PCB is a printed circuit board with thicker copper layers—typically 3 ounces per square foot (oz/ft²) or more—compared to standard PCBs (1-2 oz/ft²). This robust design allows it to handle high currents, withstand thermal stress, and provide exceptional durability. Heavy Copper PCBs are engineered for power-intensive applications where standard boards would overheat or fail, making them a go-to solution in industries requiring rugged electronics.
Where Are Heavy Copper PCBs Applied?
Heavy Copper PCBs excel in demanding environments across various sectors:
- Power Electronics: Drives inverters and power supplies.
- Automotive: Powers EV chargers and motor controllers.
- Industrial: Supports heavy machinery and welding equipment.
- Military: Enhances rugged systems like radar and weaponry.
Their ability to manage high power makes them essential for tough, reliable applications.
How Is a Heavy Copper PCB Structured?
A Heavy Copper PCB features thick copper traces and planes, often embedded in FR4 or other substrates. The structure includes multiple layers—some with copper thicknesses up to 20 oz/ft²—bonded with high-resin laminates for insulation. Vias and pads are oversized to handle current, and the design balances copper weight with thermal and mechanical stability. This rugged build supports power distribution and heat dissipation in one package.
How Does a Heavy Copper PCB Work?
A Heavy Copper PCB operates by conducting large electrical currents through its thick copper layers with minimal resistance. The wide traces reduce voltage drops, while the copper’s mass absorbs and spreads heat generated by high-power components. This dual role—power delivery and thermal management—ensures stable operation under heavy loads, making it ideal for circuits that demand both strength and efficiency.
How Are Heavy Copper PCBs Manufactured?
Manufacturing Heavy Copper PCBs involves a specialized process:
- Design Layout: Plan thick traces and thermal paths.
- Copper Deposition: Plate or laminate heavy copper onto the substrate.
- Etching: Remove excess copper with precision to form circuits.
- Layer Bonding: Stack and press layers under heat.
- Finishing: Drill vias and apply protective coatings.
This process ensures the board can endure high currents and heat without compromise.
Why Is Thermal Management Key in Heavy Copper PCBs?
Thermal management is critical in Heavy Copper PCBs because high currents generate significant heat. The thick copper acts as a heat sink, pulling warmth away from components to prevent failure. Additional features like thermal vias or metal cores enhance dissipation, keeping temperatures in check. This ability to handle heat ensures longevity and performance in power-heavy applications.
What Standards Ensure Heavy Copper PCB Quality?
Heavy Copper PCBs adhere to strict quality standards:
- IPC-6012: Defines performance for rigid PCBs, including copper thickness.
- UL Certification: Ensures safety for high-power use.
- Thermal Testing: Verifies heat resistance per industry norms.
These benchmarks guarantee that the boards meet reliability and safety expectations.
How Are Heavy Copper PCBs Tested?
Testing Heavy Copper PCBs confirms their strength and functionality:
- Current Capacity: Measures ability to handle high loads.
- Thermal Cycling: Checks performance under temperature swings.
- Visual Inspection: Spots flaws in copper or solder joints.
- Continuity: Ensures no breaks in thick traces.
These tests validate the board’s readiness for demanding conditions.
What Design Factors Shape Heavy Copper PCBs?
Designing Heavy Copper PCBs requires careful planning:
- Trace Width: Wider paths for high current flow.
- Copper Thickness: Balances power needs with board size.
- Thermal Paths: Integrates vias for heat escape.
- Layer Spacing: Prevents delamination under stress.
These factors ensure the board performs reliably under heavy loads.
Why Do Heavy Copper PCBs Outshine Standard PCBs?
Heavy Copper PCBs offer superior advantages:
- High Current: Handles power levels standard PCBs can’t.
- Heat Resistance: Manages thermal stress effectively.
- Durability: Lasts longer in harsh environments.
- Simplified Design: Reduces need for extra cooling.
These strengths make them a standout choice for power-intensive electronics.
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