Consistent Copper Substrate PCB Manufacturer in China

We Are a Precision-Oriented Copper Substrate PCB Manufacturer

We are a PCB manufacturer specializing in precision-oriented copper substrates.

With PCBMay on your side, you can rest assured that your product will be fully functional.

• Emphasize efficiency and functionality of your Multilayer boards
• Extensive AOI and E-testing
• Provide experienced CAD assistance
• Quality Management System for SMD
• Utilization of safe raw materials guaranteed

Without a question, while discussing the needs of a PCB provider, you want someone who is knowledgeable and experienced. Another element to consider is industry experience with Copper Substrate PCB.

We have extensive experience in this industry, unlike new PCB or PCBA companies.

When you hand us your order, we promise you that we know what we’re doing. Clients usually seek Consumer PCBs for Copper Substrate PCBs, with some PCBs having military specifications. Some are utilized in modern telecommunications and smartphone applications.

We’ve successfully completed large orders in a timely and hassle-free manner. We guarantee that there will never be a lack of raw materials when you work with us.

Plus, there’s more. Because we promote open contact with consumers, our personnel is easy to talk to. You can reach us via chat, email, or phone at any time, 24 hours a day, 7 days a week.

We adjust to your comfortable schedule, wherever you are in the world, because we are an international company. Our knowledgeable sales representatives can guide you through the simple Copper Substrate PCB ordering procedure.

Now, please make your inquiry.

Your Copper Substrate PCB will soon be on its way to you!

Copper Substrate PCB | The Ultimate FAQ Guide

Copper substrate PCB is one of the most demanding printed circuit boards among manufacturers. Due to its heavyweight application,  temperature handling and flexibility of use make it preferable for many applications.

Electronic items have advanced at an alarmingly quick pace in recent years. As a result, the usage of PCB is becoming increasingly prevalent. As reported by GlobeNewswire, the PCB market in China’s automobile industry might be valued at up to USD3,501 million by 2020.

Because copper is an excellent conductor of electricity, it is ideal for use as a substrate for PCBs because it can efficiently carry electrical current. You will find this article to be extremely useful if you are interested in copper substrate PCB.

PCBMay has been manufacturing copper substrate PCB since 2008. We have extensive expertise with this PCB. We cannot wait to tell you more about this PCB. So, tune in!

What Is Copper Substrate PCB?

Copper substrate PCBs are the priciest metal substrate PCBs available on the market. Compared to aluminum substrate PCB and iron substrate PCB, its heat conductivity is greater.

It is excellent for thermal transfer and architectural decorating sectors in high-frequency circuits and places. The copper substrate PCB offers substantial temperature fluctuations and precise communication equipment.

You may find copper substrates boards with immersion gold, silver, tin, or anti-oxidation treatments on copper. The copper substrate’s circuit layer must handle a significant amount of current.

So manufacturers use heavier copper foil, with a thickness ranging from 35μm to 280μm in most cases. Al2O3 and silicon powder are the primary thermal conducting components in the copper substrate’s thermal insulation layer.

Ethyl resin-filled polymers are used to make the composition, which has a low heat resistance (0.15) and great viscoelastic capabilities. It also has great durability to thermal aging and can handle thermal and mechanical stress.

It is necessary to utilize a copper plate. However, a copper plate may be used as the holding part of the copper substrate with high heat conductivity.

Copper Substrate PCB

What Are The Types Of Copper Substrate PCB?

Manufacturers use a variety of copper substrate PCBs. Copper substrates come in many shapes and sizes, each with its own set of potential uses. The following are the varieties of copper substrate PCB-

Immersion Gold copper substrates

As a surface treatment for PCB and packaging applications, Immersion Gold utilizes gold plated precisely on copper. Copper substrate does not co-deposit alongside gold, as was discovered by looking at the gold plating bath’s deposition response.

An autocatalytic process primarily drives the deposition. Also explored was how copper surface finish and conformal coating duration affected the deposit and soldering properties.

When the layer thickness is within the 30 to 80 nm range, solder spread-ability is not adversely affected by copper surface roughness. The neutral pH, auto-catalytic type thick electroless gold plating solution deposited on top of the flash gold showed high wire bonding capabilities.

To succeed, some of the characteristics must be met for the Direct Immersion Gold finish.

• Minimum copper surface corrosion during deposition
• Excellent gold Plating layer coverage
• Copper does not mix with gold.

Immersion Gold Copper Substrates PCB

Immersion Silver copper substrates

Immersion silver is more affordable than immersion gold. Immersion silver is a viable option if your PCB has connection requirements and you want to save costs. Moreover, immersion silver provides excellent flatness and contact.

It is common to cover printed circuit boards’ metal pads and through-holes with a tin-resistant and solderable coating. An immersion plating procedure is preferred, followed by a tarnish inhibitor treatment and bright etching of the pads or through-holes used.

The tarnish-preventer can be added to the immersion plating bath, or it can be used separately. The metal plating is often silver or bismuth, with copper pads and through-holes.

Immersion Tin copper substrates

Tin plating for printed circuit boards (PCBs) is known as immersion tin, and it is a distinct technique from hot air solder leveling (HASL). The PCB is made of copper and a dielectric layer.

OSP copper substrates

The anti-oxidation copper substrate PCB comprises a dielectric substrate and a copper substrate. It features an insulating thermal dissipation layer placed between the dielectric material and a copper foil layer.

An immersion gold area is placed on top of the circuit board’s copper foil layer, for welding electronic components, which are then etched. However, except for the immersion gold section, all upper circuit board surfaces are protected by a material layer. from organic welding

The utility model’s anti-oxidation PCB prevents oxidation of the copper foil layer. It provides a good welding effect and ensures the electronic properties of electronic component connections on the PCB.

What Is Copper Balancing In Copper Substrate PCB?

Copper balancing in copper substrate PCB design may bring further advantages and avoid board warpage. The PCB warpage problem is the change of the PCBs form. It is an unanticipated alteration to the PCB. During the soldering process of a warped PCB. If you solder a circuit board, you may notice that the form of the board changes.

Each layer of the PCB is uniformly plated with copper in the copper substrate PCB, thanks to copper balancing. This generates a constant conductor density on the plated surface, enhancing data communication and overall circuit efficiency.

Copper balancing plays a crucial function in the PCB manufacturing process. Due to copper balancing in the PCBs, consistent PCB thickness may be achieved during lamination. It further eliminates the possibility of low-pressure zones, which might lead to fabrication concerns requiring a re-design.

Copper Balancing

What Is The Usual Copper Thickness Of Copper Substrate PCB?

When designing a copper substrate PCB, you must consider the quantity of current that will be carried. This should indicate the maximum thermal energy change that the PCB can withstand.

Moreover, you should also consider how much structural support your copper substrate PCB can withstand by your selected thickness. Drilled holes and layered connections will also have an impact on this.

When calculating copper thickness, the kind of thick copper PCB material you choose matters. Thermal stability is an essential property for specific materials. Compared to others that quickly fall to such extremes, this will need less thickness to function.

The ounce is the most used unit of measurement for the thickness of copper on a PCB. What is the thickness of it, though? It is the thickness obtained when 1 ounce of copper is crushed flat and uniformly distributed across a one-square-foot surface. This is equivalent to 1.37 mils (1.37 thousandths of an inch).

To figure out how thick 4 oz is, multiply 1 oz thickness by 4. 1.37 mil x 4 = 5.48 mils = 4 oz.

PCB Copper Thickness

Check this video for a better understanding:

How Does PCB Thermal Management Work In A Copper Substrate PCB?

When a current travels through an electrical component, it generates heat. The level of heat generated is influenced by the power, component properties, and circuit layout. Electrical connections, copper tracing, and vias contribute to some heat and power losses in addition to the components.

Designers should attempt to produce PCBs that work and stay under safe operating temperatures to prevent failures or circuit failures. We will go through some of the most prevalent ways of eliminating excess heat from copper substrate PCBs for improved thermal management.

Improving  Copper Substrate PCB Thermal Management

PCB Design Best Practices

The following are the most critical factors to address throughout the design process.

• Dimensions and performance data for the components
• Large-scale heat dissipation systems
• The PCBs Dimensions
• Design, material, and component placement on a PCB
• Ambient temperature in the application’s context
• Effective cooling techniques such as fans and heat sinks.

It is a good idea to keep an eye on the temperature of components and systems while considering the working conditions. Factors to keep in mind include the semiconductor’s package qualities, heat dissipation properties, and more.

In most cases, you may find this data in the spreadsheet provided by the PCB maker. There are various ways to cool down overheating circuit boards, including heat pipes, fans, or even layers of thick copper. PCBs with low heat dissipation can be cooled using natural convection.

Reduce the Thermal Resistivity

Heat moves through a material significantly more quickly if it has a low thermal resistance. Because of this, resistance is proportional to the length, and cross-sectional area and conductivity are inversely correlated in a thermal pathway.

Thermal resistance

θ = t/A × K

Where,

t is the material thickness

K is the thermal conductivity factor

A is the cross-sectional area

Designers often cut down on thermal resistance by:

• Minimizing the heat path using a thin PCB
• Incorporating thermal vias to facilitate vertical heat transfer
• Horizontal heat conduction using copper foil and thick rails

Make a List of Potentially More Heat-Dispersing Elements

Itit is vital to know which parts create the most heat to remove the most heat. A designer should use the manufacturer’s datasheet to determine the device’s thermal rating. Typically, manufacturers will include instructions on reducing the amount of heat in the appliance.

Aspects to Consider Include: Component Positioning, and Orientation

You should use areas with the greatest heat dissipation for the most power-consuming components. Avoid PCB corners and edges in design unless a heat sink is present. To guarantee proper heat dissipation and appropriate airflow, components should be positioned in the center of the device.

Though maintaining a uniform temperature distribution may be challenging, avoiding grouping together high-power components. To prevent hot spots, distribute them evenly.

Another recommended approach is positioning vulnerable components such as tiny ICs, transistors, and capacitors in low-temperature locations. Thermal management can be improved by placing ICs horizontally or vertically long in convection-cooled circuits.

What Is The Difference Between Copper Substrate PCB And Aluminum Substrate PCB?

Although copper and aluminum substrate PCBs have comparable qualities and functions, there are some differences. Listed below are some crucial distinctions between aluminum and copper substrate PCBs.

1. Price

The cost of the two metal substrates is one of the essential factors in PCB design. While metal prices fluctuate, copper is usually more costly than aluminum due to its limited supply.

2. Thermal Conductivity

Due to its ‘Thermal Conductivity’, aluminum outperforms copper when it comes to heat dissipation. Copper boards are superior when high temperatures or high power levels are needed. In other words, copper is good for heat dissipation, whereas aluminum is suitable for other purposes.

3. Conductivity

Copper has a distinct edge over aluminum in terms of electrical conductivity and is the greatest choice when it comes to PCB design.  In other words, copper is perfect for situations requiring high electrical conductivity.

3. Electrical Resistance

Resistance is critical in PCB design since it affects the component’s overall operation and stability. Being denser than aluminum, copper has less resistance and is thus preferable for smaller circuits and quicker power transmission.

4. Weight

Because copper has a more significant density per unit area, it weighs more than aluminum PCB of the same design.

Aluminum is the recommended material for applications requiring low-weight construction. Copper is often utilized in situations where weight is not a factor.

Copper Vs. Aluminum Substrate PCB

What Is The Process Of Copper Plating In Copper Substrate PCB?

Copper electroplating occurs following chemical plating on the PCB hole edges. It is a cathode with carbon on the PCB panels and the hole walls. The copper surface of the PCB panel is washed, cleansed, and stimulated in several bathtubs before being electroplated.

The PCB panels’ holes are electroplated synchronously. These holes link the exterior layer parts to the inner layer elements.

This copper electroplating results in better soldering and stronger solder junctions. This is only feasible with consistent plating over the panel.

Copper plating is computer-controlled for precision and timing. Keep the panels in the bath for the specified period for best results.

The hole walls must be coated to 25 microns for optimal conductivity. 30 micron plated surface tracks are also required. With the use of 17.5-micron copper foil, the final thickness may exceed 40 microns.

PCB In Electroplating Machine

What Is The Structure Of Copper Substrate PCB?

Copper Substrate PCBs only have copper traces or interlinks on one surface.  A single-layer PCB consists of an inner and an outer layer. Here we will discuss the structure of a Copper Substrate PCB:

FR4

PCB substrates come in FR4, metal, and ceramic varieties. The most common material is FR4, an epoxy reinforced laminate.

Copper Layer

This layer of copper is a very finely textured foil of copper. It is typically used on both sides of a double-sided PCB. It is adhered to the board using heat.

Solder Mask

Ever wondered why most PCBs are green? This is because of the layer of solder masking.  The greenish tint of the boards comes from this layer, which is placed above the copper foil.

Silkscreen

White silkscreen is put over the solder mask. It is used to add numbers, characters, or inscriptions to help people comprehend the board.

Copper Substrate PCB Structure

What Are The Advantages Of Copper Substrate PCB?

A copper substrate PCB has numerous advantages. Here are a few:

• A copper substrate PCB uses a copper track to link the different components. It makes the whole unit fit in a smaller gadget.
• The copper substrate board assembly requires less time than the wire-based component connections.
• Solder flux connects copper PCB appropriately. So the board is securely kept together.
• Due to its strong attachment, a copper PCB minimizes short circuits and loose connections.
• A well-designed copper PCB decreases noise dramatically. Less electronic noise improves gadget performance.
• Copper PCBs are also very cost-effective. Thus, it cuts the cost of technological equipment and makes them accessible to everybody.

What Dielectric Materials Are Used On Copper Substrate PCB?

Dielectric materials provide a copper substrate PCBs non-conductive substrate layer. A steady dielectric constant across an extensive frequency range is desirable for safety.  Listed below are some common PCB dielectric materials.

FR-4

FR-4 is the most widely utilized PCB dielectric material and meets NEMA specifications. F4 is a woven epoxy compound having fire-resistant (FR) characteristics.

CEM

NEMA lists CEM as a PCB material family. They work well in high-density environments.

Polytetrafluoroethylene (PTFE)

PTFE is a synthetic fluorine-carbon polymer. It is often used to cover non-stick cookware under the trade name Teflon. PTFE has a high glass transition temperature of 160-280C.

Polyimide

Polyimide is the finest PCB dielectric material for copper PCBs. In addition to its electrical qualities, polyimide is very flexible and chemically resistant.

PCB Dielectric Material

What Are The Design Methods For Copper Substrate PCB?

Copper Substrate PCBs are made using epoxy resin for their adhesive properties. The PCB features copper substrates or foils on both sides with excellent thermal and electrical conductivity.

For increased conductivity, a copper substrate manufacturer may employ two to three layers of copper in the center of a PCB. Embedded multilayer copper PCBs improve performance and durability.

Manufacturers will sometimes employ a heavy-copper basis for the PCB. These thick copper PCBs work under the most challenging situations. So it is used in electrical devices like Power devices, nuclear power plants, and renewable energy sources.

PCB Design Guideline

How To Quality Control The Copper Substrate PCB?

Copper Substrate PCB quality control involves effective management, monitoring, and measuring PCB design, production, and inspection.

PCB Design Quality Control

• Verify PCB design file validity.
• Ensure PCB manufacturability.
• Ensure testability and normalization.

PCB Production Quality Control

• Ensure manufacturers’ capability
• Constant checking and validation is required prior to manufacture.
• Key PCB manufacturing methods should be closely monitored.

PCB Inspection Quality Control

Visual examination or professional equipment is used to monitor and measure the PCBs. You should save the inspection result. Specific acceptance rules must be created if particular requirements must be met.

PCB Quality Control

What Are The Safety Concerns In Copper Substrate PCB Manufacturing?

The solder used to connect copper substrate PCBs includes lead, which is dangerous. Solder vapors are harmful to health. Hence soldering must be done in a confined atmosphere.

Before venting the fumes into the environment, they must be extracted and cleaned. Many PCB-based electrical goods are outdated after 12-18 months.

Many environmentalists are worried about these old goods ending up in landfills. Devices recycling includes renovating outdated items and reselling them to clients who do not need or want newer, more advanced electronics. Disassembling other electronics salvages computer components for resale or reuse.

PCB Safety Concern

What Are The Drawbacks Of Copper Substrate PCB?

Copper substrate PCBs have the following drawbacks:

• The PCB is costly compared to other PCBs.
• It is not re-workable. If it breaks down, you cannot fix it.
• It causes signal delay.
• The process of application of this PCB is complicated. You need a specialist to get your work done.

What Are The Applications For Copper Substrate PCB?

Thanks to copper substrate PCBs, various sectors have seen breakthroughs. As a result, copper PCBs may be used in multiple industries. Adding copper circuit boards to the mix opens up a whole new world of possibilities.

• They are found in solar energy converters. It considerably improves the converters’ efficiency.
• Copper substrate PCBs are used extensively in renewable energy systems nowadays. In addition, it is employed in pumping stations.
• Due to its high conductivity and dielectric capacity, copper substrate PCB is used in high-power rectifiers.
• Many other types of communication equipment, such as trains and airplanes, use copper substrate boards.
• Overload relays, power line monitors, and various torque control devices will all use this technology.

Copper Substrate PCB In Solar Panel

How Can You Successfully Choose The Best Manufacturer Of Copper Substrate PCB?

Choosing a copper substrate PCB provider is no longer a difficult task due to the abundance of copper substrate suppliers.  Finding a copper substrate PCB manufacturer should include the following:

1 Professional experience

Before purchasing bulk or single copper substrate, you must know the supplier’s expertise.  If a supplier has previously made a similar item, they are certain to be acquainted with common quality difficulties.  They can identify and rectify difficulties before they impact the whole order.

2 Quality of the product

Checking product quality is also vital before employing a supplier.  Provider quality is defined as the ability to provide labor and goods that answer customer concerns.

3 Price

Notably, low cost does not necessarily equate to the greatest value. You can lose money if your supplier’s product or service is low quality.  Choosing a low-cost supplier means risking it all. Because low pricing always equates to a low-quality copper substrate, there is a risk of business losses.

4 After-Sales Service

Ongoing assistance helps customers get the most out of their purchases. This might contain both current features and new applications or capabilities.

Checking supplier after-sales service draws consumers owing to supplier quality and efficiency, resulting in repeated purchases. Happy consumers encourage repeat visits. After-sales service improves company sales.  Poor post-sale service might hinder client satisfaction and hence development.

5 Certifications

The correct vendor’s quality management certification may help manufacturing organizations develop systems and controls that lead to fewer faults and more profits.  A supplier’s ability to follow clear documentation procedures is another sign of a quality provider with quality certifications.

With certification, a provider may show its clients that its methods and goods satisfy a higher level of quality.

Copper Substrate PCB Manufacturer

Conclusion

Copper Substrate PCBs changed the face of electronics. Their perfection has enabled the production of modern technologies that were deemed unattainable just a few years ago.

We really hope you understand Copper substrate PCBs and can choose the correct manufacturer. PCBMay is one of the largest Copper Substrate PCB makers in China. For additional information or to get a quote, please contact us.