Efficient Copper Clad PCB Manufacturer in China

PCBMAY – The Excellent Copper Clad PCB Manufacturer

At PCBMay, we only use the best quality Copper Clad Laminate to make Copper Clad PCBs. Our manufacturing process is quality assured, our base materials are outstanding.

• Strong, flat, smooth & durable
• Industry grade – no deviation, no warping
• Standard Electric Performance – Tg, Dk, and Df checked
• The correct process for solder mask application
• Water absorption – conform to IPC standards

PCBMay can help you with the prototype of your PCB order. If there is already a design developed, you can just send us the Gerber file. We will facilitate product development from beginning to end. This includes correct monitoring of the production process to strict inspections.

In case there is a problem with your Copper Clad PCB order, we will help you find out the root cause. PCBMay will furnish a full 8D report for this since we want to assist you to the full extent possible.

Aside from these good qualities, we also offer responsive customer care and service. Our salespeople are trained to communicate well with you. We want to understand your pain points, so we can offer a suitable PCB design or solution. You can give us a call any time, wherever you are in the world. We will answer your call or message instantly!

From 4 Layer PCBs to 40 Layer PCBs, we have all you need. PCBMay can give you worry-free solutions to all your Copper Clad PCBs queries. Don’t hesitate, and don’t wait.

Call PCBMay now, and let your business grow!

Copper Clad PCB: The Ultimate FAQ Guide

It is the most common material type PCB in the PCB industry. PCB is the heart of all electronics in the modern era. No electronics can operate without a PCB inside them.

Copper clad is the principal material of typical PCBs. For years, copper-clad laminate has been used to make copper-clad PCBs. Do you want to know more about them?

This article will try to educate you with several fundamental questions answered about the copper-clad board. Let’s begin the journey.

What Is Copper-Clad PCB?

Copper-clad or copper foil is a conductive base material of PCB. A copper-clad PCB sheet with reinforced fiberglass material is used to make a PCB through lamination. This lamination happens with melted resin and is applied to the single or both sides of the copper-reinforced material. These types of PCBs are called copper-clad PCBs.

Also, copper and steel, copper and aluminum, and other combinations form copper clad. The nominal copper clad board thickness is 0.50, 0.70, 0.80, 1, 1.20, 1.50, 1.60, 2, 2.40, 3.20, 6.40 mm. This thickness changes to 0.7 to 1.50 mm for paper-based copper-clad lamination.

Copper Clad PCB

The nominal thickness of copper-clad laminates indicates the thickness after the PCB is completed. The raw copper thickness of PCB is divided into three different numbers, which are 35 µm, 70 µm, and 105 µm. A significant portion of copper-clad PCB uses 70 µm copper thickness.

Though the thickness depends on the purpose and the other materials of the PCBs.

How To Make A Copper-Clad PCB?

It is the most common PCB in the PCB industry. To design a copper-clad PCB, you have to follow some gradual steps of the design rules of a PCB. To make a successful copper-clad printed circuit board, you must follow the proper design technology and the right software.

Determine The Component Mounting Technology

Before designing your copper-clad board, first, determine which component mounting technology you want to use. The component mounting system means how you would like to place the components on your Copper clad boards.

Surface Mounting Technology (SMT) and Through-Hole Technology (THT) are the two available types of component mounting technology. The copper-clad PCB board will be designed and then collaborated with the mounting technology.

Draw The Schematic Of Your PCB

Draw the schematic design with the computer software. The schematic is the blueprint of your PCB. It will then master the entire structure of how the PCB will look with different circuitry.

Make Your Copper-Clad PCB Layout Design

Now, design a PCB layout based on the schematic diagram of your PCB in the Altium or other PCB design tools. Import the components and different circuitry designs from the schematic to the PCB layout by designing software.

PCB Layout

Keep the analog signal traces away from the digital signal traces to prevent signal noises and loss.

Order The PCB Stackup

Determine the PCB layers’ number, order of the layers, spacing, and copper-clad board thickness. This will help you to order your PCB stack up properly.

Component Choosing

Choosing the right components for the copper-clad PCB is necessary. The component selection depends on the purpose of the PCB. The essential components are the same almost on all PCBs. Pick the quality components for a long lifespan.

Etch The Traces

Etch the traces to conduct electric current on the board. Keep the right thickness for traces.

PCB Fabrication And Assembly

Assemble your PCB with predetermined components. Use soldering for through-hole or SMT technology you previously determined to join the copper-clad board components.

Proper copper-clad PCB material should be employed to fabricate the PCB’s outer and inner regions, such as pads, holes, and exposed copper traces. Fabrication will prevent the corrosion of your copper-clad PCB.

Check on how could you design your copper-clad PCB:

What Are The Associated Materials Used With Copper-Clad On A Copper Clad PCB?

Besides copper-clad laminate, other materials are used to make and fabricate a copper-clad PCB. Here are the few most popular and common materials used in PCBs, along with copper-clad laminate.

Prepreg

Prepreg is a glass-reinforced epoxy resin coating fabric. Prepreg liquified and hardened between a specific range of temperature, which is generally above 300 °F.

Laminate

CCL or copper-clad laminate is composed of prepreg sheets joined together with high pressure and temperature.

Copper Foil

The traces on the PCBs and the circuits on the laminated surface are etched using copper foil.

Solder Mask

A solder mask is an epoxy covering that protects the exposed areas of copper-clad boards from corrosion.

Green Solder Mask On PCB

Silkscreen

Silkscreen is the white letters that are seen on the solder mask coating of the copper-clad PCBs. The lettering with silkscreen provides the orientation of the PCB components.

What Is The Layer Stackup In Copper-Clad PCB?

In general, copper-clad PCBs are identified by their layer number. The arrangement of the layers and insulating layers of a PCB is called the PCB layer stack up. The multilayer stack-up design structure provides several benefits and additional circuitry possibilities on a single copper-clad board.

PCB Stack Up

• A PCB layer stack can help you in diminishing the affectability of copper praise PCBs to external upheaval. On a high-speed copper clad PCB plan, furthermore decreases radiation, control impedance, and crosstalk issues.
• The appropriate PCB layer stack can likewise work on your plan’s Electromagnetic Suitability.
• A decent layer PCB stack-up can help you adjust the need for minimal expense, effective creation processes with signal honesty contemplations.

The PCB layer can range from 1 to 100 or more.

What Are The Types Of Copper-Clad PCB?

Though the fundamental objective of the copper-clad PCBs is the same, different types of PCBs are available in terms of needs. Here are some of the various copper-clad PCBs mentioned below.

Single-Sided PCB

Single-sided copper-clad PCBs are the most common PCBs in the PCB industry. With a single conductive layer on it, components are soldered on one side of the PCBs. The other side contains the etched conductive traces.

Double-Sided Board

A double-sided PCB is created by applying a thin copper layer to both sides of the PCB. The PCB has holes that allow connections between the two sides of the double-sided copper-clad board.

On a double-sided PCB, surface mounting or through-hole mounting techniques can put the electrical components.

Multilayer PCB

At least three copper layers are used in multilayer PCBs. For making a multilayer PCB, multiple copper-clad boards are sandwiched together. Also, an equal number of insulating copper-clad PCB sheets are used.

To correctly combine the layers, intense pressure and high heat are used to glue them together.

Rigid PCB

Rigid PCBs are made of solid and inflexible fiberglass substrates. They are not bendable and adaptable. Rigid PCBs are easier to make with cost-effectiveness. They are also hard to fit in a compact area.

Flexible PCB

PCBs that are flexible may be bent. They can fit into small spaces. Flexible PCBs are made using flexible polyamide and liquid crystal polymers. The heat resistance of flexible PCBs is higher. Because of this, they are very adaptable and may be utilized to package tiny electrical equipment.

Flexible PCB

Rigid-Flex PCBs

Both rigid and flexible PCBs are integrated into rigid-flex PCBs. The rigid-flex packaging is appropriate when ultra-light packaging is required. The rigid-flex PCBs are smaller and lighter thanks to electrical interconnection.

What Are Vias And Their Uses In Copper-Clad PCB?

Vias are plated through holes in copper-clad PCBs to course electrical paths starting with one layer then onto the next, or starting with one side then onto the next. The vias on your copper-clad PCB might be bored precisely, and the electrical associations could be made wherever around the board.

For double-sided copper-clad sheets and multi-facet PCBs, PCB vias are needed to make electrical associations. They set up ways for sufficient electrical flow to go between the board’s different layers. Vias are a kind of divert that fluctuates fit as a fiddle contingent upon the sort.

Mainly three types of vias are available to establish the electrical connections through the copper-clad PCB.

Through-Hole Via

The most frequent vis type is the through-hole via. It passes through the PCB layers, allowing every layer of your copper-clad PCB to link through through-hole vias.

Vias On PCB

Buried Via

The inner layers of the copper-clad PCBs might be connected via the buried vias. Outside of the boards, the holes are invisible.

Blind Via

You’d be able to link the surface layer of your PCB to the next layer using the blind vias on the PCBs. Aside from the surface, you wouldn’t be able to see the vias’ hole on the opposite side of the PCBs.

What Are The Applications Of Copper-Clad PCB?

The uses of copper-clad PCBs are vast in electronics. Since copper-clad laminate is one of the fundamental materials of PCB boards, you will find copper-clad PCBs in almost every electronic device.

The following are the most popular applications for copper-clad PCBs.

Medical Sector

Automation in the medical sector is growing so fast. Copper-clad PCBs are playing significant roles in medical devices such as:

• CT scan, CAT, and ultrasonic scanning system.
• The devices are used to monitor heart rate, blood glucose, and blood pressure.
• Insulin and patient-controlled analgesia monitoring system.
• Pacemakers and other inside devices require small PCBs to work.

CT Scan Machine

Consumer Level Electronics

• Tablets, radio, smartwatches, and communication devices
• Computer and computerized devices
• Home appliances such as refrigerators, microwave ovens, lighting, TVs, sound systems, etc.

Light Emitting Diodes

• Lighting for the home
• Lighting for the workplace
• Lighting for automobiles
• Displays on computers
• Lighting for medical purposes

Industrial Devices

• Equipment for manufacturing
• Solar panels, dc to ac converters, and other power devices are examples.
• Instruments for measuring

Automobile Sector

• Navigation system
• Autopilot
• Control system
• Sensors for blind spots, objects

Aerospace PCB Sector

• Power generation
• Equipment for monitoring
• Equipment for tracking
• Equipment for communication, etc.

Maritime Sector

• Navigation
• Communication equipment
• Control system

Defense

• Communication
• Control system
• Gadgets

How Do Thermal Properties Impact A Copper-Clad PCB?

Prepreg reasons are changeable when they go through different thermal states. The impact of the thermal state on the copper-clad PCBs is very considerable.

I. Glass Transition Temperature

Copper-clad PCBs substrate gets softened within a specific temperature and returns to its previous state when the temperature gets off. This temperature is known as glass transition temperature (TG).  The range of Tg should be under 200 °C to 250 °C.

Tg Variation On PCB Laminate

II. Decomposition Temperature

Your copper-clad PCB could lose its overall 5% of mass by the decomposition temperature permanently. The Td range should not be under 250 °C.

III. Coefficient Of Thermal Expansion

The state of expansion for the copper-clad PCB is the coefficient of thermal expansion(CTE) while the PCB goes under its supported Td. The unit of CTE is measured in parts per million (ppm). The safe range of CTE is up to 70 ppm.

IV. Thermal Conductivity

Thermal conductivity is the state of PCB to conduct heat. If the thermal conductivity is higher, it is assumed that the performance of the PCB is also significant. The copper’s thermal conductivity is 386 w/mk, which is excellent.

What Are The Electrical Characteristics Of Copper-Clad PCB?

The ability to pass an electric current through the copper-clad PCB is known as the electrical characteristics of the board. The following are the different electrical characteristics of copper-clad PCBs.

Dielectric Constant (DK) and Relative Permittivity (Er)

The DK and Er impact the signal integrity and the impedance of PCBs. A stable DK is expected to ensure signal integrity.

Figure 09- Dielectric Thickness Range

Volume Resistivity,ρ(Ω/m2)

To keep the proper isolations between the layers of the PCB, the ρ should be kept as high as possible.

Surface Resistivity (ρS)

The blockage of a dielectric material’s surface to protect and power is surface resistivity (S).

Which Chemical Attributes Should Be Ensured For Copper-Clad PCBs?

Chemical characteristics should be ensured for the durability of your copper-clad PCB. That is why different chemical properties should be checked before selecting the materials.

Flammability Properties- UL94

UL9 is the standard for the flammability of the epoxy plastics of your copper-clad PCB. The materials should be under the UL94 flammability standard.

UL94 Compliant FR4

Moisture Absorption Capability

The moisture absorption of the materials influences the electrical and thermal characteristics of copper-clad PCBs. Moisture absorption ranges from 0.01% to 0.02%.

How Is Surface Mount Technology Used On Copper Clad PCB?

As we mentioned before, the SMT is the automated process of mounting electrical components on copper-clad PCBs. SMT happens through an automated surface mount component machine.

The  SMT follows the following steps.

Material Preparation

The first stage is to prepare the SMC and the copper-clad PCB for the SMT. Tin, silver, gold, etc., surface finishes are already applied to the PCB by this time. If any flaws are found on the PCB, they should be resolved.

Preparation Of Stencil

For ensuring the fixed position of the PCB on the machine along with solder paste printing, the stencil is used. The stencil is produced according to the surface finishes on the PCB.

Printing Of Solder Paste

Solder paste is used to connect the SMC primarily, and the surface finishes on the PCB. It is a mixture of flux and tin. This happens with the stencil between 45 °C to 60 °C temperature.

Placement Of The SMC

A conveyor belt carries out the PCBs to the machine, and the components are placed on them with a pick-and-place method.

Reflow Soldering

The boards are then carried to the reflow oven after SMC has been placed on them. By raising 1 to 2 °C every second, the temperature rises from 140 °C to 160 °C. The copper-coated board will next be soaked for 60 to 90 seconds in the soaked zone at temperatures ranging from 140 to 160 degrees Celsius.

Reflow Soldering Machine

After this, the boards will again be placed into a zone where the temperature will be raised by 1 to 2 °C per second up to the peak of the temperature to melt the soldering tin, which is between 210 °C to 230 °C.

After finishing the joining, the boards ought to be exited from the heat zone and frozen, and it ensures the permanent joint of the components with the boards.

Now clean the boards and check the durabilities through the various PCB testing methods.

How To Prevent Corrosion On Copper-Clad PCB?

The oxidation of copper on printed circuit boards is known as corrosion. When oxygen attaches to the metal of copper-clad PCBs, corrosion develops. As a result, metals lose their chemical properties.

Corrosion must be overcome to safeguard the PCBs and guarantee optimal functionality. Corrosion protection on copper-clad PCBs is not a difficult task.

Corroded PCB

Chemical coatings, such as solder masks, should be applied to exposed parts of the PCBs. Alternatives include epoxy lamination and aerosol spray.

Surface finishes with gold, tin, silver, or palladium are another option for preventing corrosion on copper traces. Depending on your budget and requirements, you may choose from a variety of surface finishes.

Why Is Controlled Impedance Important For The Flawless Performance Of Copper-Clad PCB?

Impedance on PCBs is the combination of capacitance and inductance that ensures a perfect signal transmission.

During high temperatures and high frequencies, the controlled impedance assures faultless signal integrity across the copper traces of the PCBs. This also prevents signal wetness, signal devaluation, and signal bending.

Controlled Impedance Is Necessary For Flawless Signal

The uncontrolled impedance of the components occurs when the impedance is not in the proper state. Signal loss as a result of uncontrolled impedance leads to a performance decline. It’s also possible that components will fail unexpectedly.

The only method to get the maximum signal integrity is to ensure regulated impedance/ matching impedance.

Which Grounding Techniques Are Used To Ground The Copper Clad PCB?

PCB Ground

The alternate path for flowing the electric current to the ground on the PCBs is called grounding. This protects the board from harmful electric shock and faults.

The currents on the PCBs are supplied by the active wire and safely returned to the ground via the neutral connections.

PCB Grounding

Different grounding techniques are used for grounding the copper-clad PCBs.

● Ground Plane

The ground plane is one of the most often used grounding methods. To ground the PCB, a large amount of copper foil is utilized. During PCB fabrication, copper foil is used to cover the open portions of the boards.

● Ground Plane Vias

The ground planes would be linked through discrete vias located throughout the PCB. You may connect the layers of the PCBs using vias (holes on the PCBs).

● Connector Grounds

The grounding should also be connected to all connection pins on copper-clad PCBs. The ground pins aid parallel signal conductivity.

How Could You Avoid High Temperature On Your Copper Clad PCB?

Heating is a common issue for PCBs when it is operating. High frequency, high electric current passing, and high-signal integrity may produce high temperature on a PCB.

Overheating causes various problems to copper-clad PCBs. This might drive the PCBs to permanent damage or temporary performance drop. So, avoiding high-temperature copper-clad PCBs is essential.

High Temperature Can Cause Damage To The PCBs

You should take the following steps to avoid the high temperature on a PCB.

• Use a heatsink. All components of the PCB produce heat. The heatsink will consume the heat and keep the PCB cool.
• Use cooling fans. You will see most electronics nowadays use the cooling fans feature to keep the temperature low.
• More thickness of the boards conducts less heat. Use a thick board.
• Apply laminates to prevent damage to the copper-clad PCB. It is one of the most efficient ways to keep the temperature low.

What Are The Types Of CCLs Used In Copper Clad PCB?

CCL refers to copper-clad laminate. Different laminates are used on copper-clad PCBs for more strength, performance, flame resistance, and durability.

I. FR4

FR means flame-retardant, 4 refers to the grade. It is the most common thermostat plastic epoxy laminate, which is standard UL94V-0 standard grade. It contains highly thermal, mechanical, and electrical characteristics.

It is the glass cloth with the lowest cost as well. It has a balanced strength-to-weight ratio, which makes it ideal for most PCBs. It is prevalent for multilayer PCBs within 14 layers.

Its high performance with higher thermal stress in high-speed PCBs with lower cost makes it the most popular in the PCB industry.

II. Polyamide Laminate

Polyamide laminates are more adaptable and reliable in higher temperature and high-performance PCBs than FR4 epoxy laminates. However, it costs slightly more than FR4 as well. It also improves its electrical performance compared to FR4 with more survivability.

Polyamide laminates have thermal cycle stability with minimal expansion. As a result, it is better suited for greater layer count PCB construction.

III. Teflon

Teflon offers excellent thermal stability with electrical properties, which helps it to be popular for high-speed circuit building. It is as well as more expensive than polyamide but provides more high-speed capabilities than polyamide also.

IV. Aluminum

Aluminum is one of the basic materials to make PCBs. It is generally used for making high-frequency PCBs.

Aluminum As Base Material Of PCB

V. Flexible Laminate

However, it does not jeopardize electrical continuity. Flexible laminates are built of a thin plastic sheet rather than glass cloth. Flexible circuits are constructed of a foldable and bendable flexible laminate.

Flexible laminates are made from high-temperature materials such as polyamide and liquid crystal polymer.

How To Find A Quality PCB Manufacturer In China?

Finding a quality PCB manufacturer is not that difficult. A good and quality PCB manufacturer will hold some notable features that differentiate them from average manufacturers.

• A lot of industry experiences are on their bag
• They can produce bulk production on time
• Deliver significant customer services
• Facilitate vast and high-tech workplace
• They provide cost-efficiency in manufacturing PCBs.

Can You Etch Copper Clad PCB?

Etching is the process of making conductive traces on the PCBs. For passing the current flow through the copper-clad PCBs, etching is a must. So, etching is one of the vital stages of PCB design.

There is no doubt that you can etch copper-clad PCBs.

Let’s check how to etch a copper-clad PCB:

Final Thoughts

When you think about manufacturing copper-clad PCBs, an experienced manufacturer like PCBMay should be your first consideration. We provide large production of Copper clad PCBs.

We have a vast area of experience in PCB production with an extensive research wing. We can fulfill your desired demand in the most efficient way.