Buy High Performance Heavy Copper PCBs from China Suppliers - Ideal for Power Converters & Vehicles with Superior Heat Dissipation Companies, Factories
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Buy High Performance Heavy Copper PCBs from China Suppliers - Ideal for Power Converters & Vehicles with Superior Heat Dissipation Companies, Factories

Buy High Performance Heavy Copper PCBs from China Suppliers - Ideal for Power Converters & Vehicles with Superior Heat Dissipation Companies, Factories

Discover high-quality power converters, including AC-DC and DC-DC models, designed for vehicles and equipped with strong current-carrying capacity and excellent heat dissipation. As a leading factory in China, we are committed to providing reliable and efficient solutions for your power conversion needs. Partner with trusted suppliers to ensure optimal performance and durability in every application. Choose our products for unmatched quality and innovative design tailored to meet the demands of modern vehicles
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Product Description

What is Heavy Copper PCB?

▶ The core is used in high-current and high-power scenarios (such as power supplies, new energy, industrial control, etc.). The key points of its design, manufacturing and application are as follows:

Core features and application scenarios

🚀Core advantages

  • • Strong current-carrying capacity: The current-carrying capacity of 70μm copper foil (2 ounces) is approximately twice that of 35μm copper foil (1 ounce) (under the same line width).
  • • Good heat dissipation: The thick copper layer can quickly conduct heat, reducing the risk of overheating of the device.
  • • High mechanical strength: Thick copper enhances the PCB's resistance to bending and impact.

🛠️Typical applications

Power converters (AC-DC/DC-DC), BMS for new energy vehicles, industrial frequency converters, control boards for welding machines, etc.

Heavy cooper PCB

Key design points

1. Selection of copper foil thickness

• Common specifications: 70μm (2 oz), 105μm (3 oz), 140μm (4 oz), up to 420μm (12 oz).
• Matching: Large current (≥5A) use 2-4 oz; Ultra-power (≥20A) use 6-12 oz.

2. Trace and current-carrying capacity

I = K × W × T0.83

• Keep traces short and wide to avoid narrow necks.
• Use parallel multi-layer copper foil to enhance capacity.

3. Via and pad design

• Vias: Increase diameter (≥0.5mm) and number (est. 1A per hole). Wall plating ≥20μm.
• Pads: Enlarge size (0.2-0.5mm larger) to prevent heat dissipation issues during welding.

4. Heat dissipation and insulation

• Heat dissipation: Design "copper sheet heat sinks" or metallized via arrays.
• Insulation: Widen wire spacing (≥0.2mm for 70μm copper) to prevent creepage.

Manufacturing process difficulties and control

⚙️ 1. Copper foil lamination and etching
Requires high-temp/high-pressure (180℃/4MPa) lamination. Etching is slow (~1μm/min); stepwise etching reduces side etching (≤0.05mm).

⚖️ 2. Lamination and warpage control
Use "symmetrical structure" (consistent copper thickness on upper/lower layers) and rigid support layers to prevent warping (≤0.5%).

✨ 3. Surface treatment
Prefer tin plating or nickel-gold plating to avoid OSP issues. Use "solder mask opening windows" for better bonding force.

Core Summary

The core of heavy copper PCBs is "high current carrying capacity + heat dissipation". Success depends on matching copper thickness to current requirements in design, while solving etching and warping challenges in manufacturing. Ideal for high-power industrial and energy scenarios.

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Frequently Asked Questions

What defines a PCB as "Heavy Copper"?
A PCB is generally considered "Heavy Copper" when the copper thickness exceeds 3 ounces (105μm) per square foot. However, even 2 ounces is often treated with similar design considerations in high-power circuits.
What is the maximum copper thickness you can manufacture?
While standard heavy copper goes up to 4 ounces, extreme applications can utilize up to 12 ounces (420μm) or more through specialized manufacturing processes.
How does heavy copper improve thermal management?
The increased mass of copper acts as a natural heat sink. It conducts heat away from power-generating components more efficiently than standard copper, reducing the overall thermal stress on the board.
Can heavy copper be used on multi-layer boards?
Yes, heavy copper can be used on internal and external layers of multi-layer PCBs. Often, designers use a "symmetrical" stack-up to prevent board warping during the lamination process.
Does heavy copper affect the minimum trace width?
Yes. Due to the etching process for thicker copper, the minimum trace width and spacing must be increased. For example, 3oz copper typically requires wider spacing than 1oz copper to avoid short circuits and ensure clean etching.
What surface finishes are recommended for heavy copper circuit boards?
Tin plating or ENIG (Electroless Nickel Immersion Gold) are preferred finishes for heavy copper boards, as they provide robust surface protection and ensure strong solder joints under high-current thermal conditions.

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