Copper Base PCB Manufacturers

A PCB or Printed Circuit Board, also known as Printed Wiring Board (PWB), is a laminated sandwich structure composed of conductive and insulating layers. They are mainly used to mechanically support and electrically connect various circuits of any electric device. As technology advances day-to-day, the evolution of these PCBs is also seen. Highly dynamic and revolutionary inventions have led to the emergence of copper-based PCBs.

Copper PCBs are used widely because they have high thermal and electrical conductivity. So, these copper PCBs can be used in even the smallest and most advanced electronic devices. 

However, most people are still unaware of the advantages and efficiency of these copper-based PCBs. So, in this article, we shall talk about –

1. The Basics of Copper Base PCB
2. Metal Core PCB Design Guidelines
3. Advantages of Copper Backed PCB
4. Disadvantages of Copper Backed PCB
5. Guidelines for Metal Core PCB Prototyping Sheet Safety
6. Differences Between Aluminum PCB and Copper PCB
7. Applications of Copper PCB

The Basics of copper-based PCB:

The basics of copper PCBs start with their nomenclature. There are various names assigned to the same structure. Some know them as copper-based PCBs, copper-clad PCBs, and even copper-substrate PCBs. However, despite having different names, the functionality and the characteristics of this device remain the same. 

Copper PCBs are multi-layered and include a copper base, an insulating layer, and a copper circuit layer. All these layers have different functions adding to the quality and effectiveness of the PCB. A copper-based PCB is mainly divided into 2 broad categories. These categories are segregated on the basis of their performance capacity and functioning. 

1. Embedded copper coin PCB
2. Buried copper coin PCB

One must remember that an ideal copper PCB will be copper-based instead of the commonly used FR4 base. This brings several benefits to the user, which we will discuss further in the article as we proceed. 

Also, the copper base is made more durable and long-lasting using wood pulp or glass fiber. This ensures rigidity and reinforcement. It makes the PCB more powerful when used for real applications. 

Guidelines of a metal core PCB design:

The metal core PCBs (MCPCB) is surrounded by epoxy resin during manufacture owing to the adhesive quality of the resin. A copper-substrate foil on each side of the PCB is wrapped, and a copper circuit board is sandwiched in the middle. This copper circuit board is inserted to ensure high thermal and electric conductivity. Since copper is the most common of all other metals used for this purpose, these PCBs are also called metal-clad PCBs. 

For developing a multi-layer copper PCB, the manufacturer will have to use two or three copper layers in the middle part to increase the conductivity. These multi-layered copper PCBs are mostly embedded to improve their performance and ensure better reliability. 

However, the manufacturer sometimes uses a heavy copper base to make the PCB. These thickened middle layers of copper maintain regular functionality in even extreme conditions. They can bear a relatively higher thermal and electrical energy without failure. Thus, many electronic device manufacturers use these for many purposes, like in UPS systems, nuclear power centers, renewable sources of energy, etc. 

Advantages of copper-based PCBs:

Copper PCBs have many advantages like –

1. The internal connections between various components in a copper-based PCB are made using a copper track, making the whole unit very compact. 
2. The copper PCBs come with transparent labeling. So, in case of any water damage, it is quite easy to identify and replace the damaged part. Also, this ensures easy and convenient installation. This is quite beneficial in case of damage, so you don’t have to replace the entire unit; you can just replace the damaged part of the component. 
3. A printed and transparently labeled copper PCB takes less time to assemble than traditional worn-off wire-based component connections. 
4. The whole copper PCB is bound using solder flux. This ensures zero mobility of the board inside the device. The soldering holds the board tightly to the surface, thus, preventing its movement. 
5. A copper-based PCB eliminates the risk of any short circuit because it has no loose connections at all. The attachments are soldered so tightly that they don’t allow a single connection to move on the surface. Ence, copper PCBs are safer to use. 
6. If the copper-based PCBs are installed correctly, it can significantly reduce the noise. Thus, your electronic device can work more efficiently without getting exhausted on the battery backup. 

Thus, these copper PCBs are not just durable and rigid but are also highly cost-effective and log-lasting. Consequently, those devices with copper-based PCBs installed also cost less. 

Disadvantages of copper-based PCBs:

Like any other electronic item, copper-based PCBs also have some demerits. These are –

1. They are not designed to carry high electric currents due to their small and compact size. Hence, these copper PCBs can only be used in small devices with less current.
2. The soldering process needs to be carefully done and requires minute attention because all the connections are quite tiny, so over-soldering can lead to overheating of these connections. Hence, the whole structure may fail to damage the entire component. 

Guidelines for Metal Core PCB Prototyping Sheet Safety:

An ideal metal core PCB – aluminum and copper – must have the ultimate protection. You can protect them using the following tips –

• These metal PCBs come with two layers of plastic film on top and bottom. 
• When you start manufacturing the PCB, you cut through the top film and separate the two sheets. The top film exposes the copper side. 
• Now clean the copper side using a sponge to look bright and shiny.
• Once the shining appears, clean it using acetone. 
• Once the cleaning is done, the metal-core PCB is good to go and safe to use. 

However, it is always advisable to purchase copper PCBs from a trusted brand or shop for additional safety purposes. However, all the manufacturers will deliver the best copper PCBs; a few are better. 

Differences between Aluminum and Copper PCB:

Both aluminum and copper PCBs result from highly advanced technological development in the electronics and communication industry. Both are good according to their uses and applications. However, there are certain differences in the functionality of both. So, if you want to manufacture good quality PCBs, it is crucial that you understand the differences between the two – 

• Copper PCBs have twice thermal conductivity in comparison to aluminum PCBs. Therefore, copper PCBs can dissipate heat more effectively as they are more thermally conductive. 
•  The copper-based PCBs have smaller shrinkage and warp age than the aluminum ones, so you can process the copper PCBs into a dedicated metalized hole. This is not possible with an aluminum PCB.

Applications of copper PCB:

Copper-based PCBs have various applications like – 

1. Used in solar power converters.
2. Used in pumping plants.
3. Used in high-power rectifiers due to their dielectric capacity.
4. Used in railway communication devices.
5. Used in overload relays, monitors of the power line, and torque control devices of different sectors. 

Conclusion about Copper Base PCB Manufacturers 

Thus, we can say copper-based PCBs have truly revolutionized the electronic arena. Their emergence and discovery enabled us to generate many modern devices in a compact size. This was unthinkable a few decades back. But now, with copper PCBs, it is possible to take our technological and electronic communications to new heights.