Your Very Best Headphone PCB Manufacturer in China

PCBMay Masterfully Manufactures Many Types of Headphone PCBs

The vital element to a great audio experience with any listening device is the Headphone PCB. With a Headphone PCB from PCBMay, you will experience sound quality like no other.

• Quality assured, comply with latest ISO standards
• Rogers advanced wireless material available
• Possible to fast-track your order
• Can give you professional CAD support
• No MOQ (Minimum Order Quantity)

PCBMay is confident in supporting any of your Headphone PCB requirements. Whether you are an EMS or a direct consumer, we will give you the best PCB at the lowest price.

Unlike other expensive PCB manufacturers, we can guarantee you high-end PCB raw materials (PCB laminates and surface finishes). We use these high-end materials on all our PCBs, not just your Headphone PCB. In fact, we can support all other related PCB needs for audio, like Audio Amplifier PCB, Stereo PCB, Speaker System PCBs, and all other PCBs for sound mixing (e.g. DJ Controllers, PA systems, audio interface, etc.).

Do you want to inquire now? Then, just call, message or send us an email. Our sales team is trained well so that they give you follow-ups of your order at your convenient time. After you contact us about the Headphone PCB order, we’ll give you a speedy quote in the shortest time possible.

We are here to help you with a business partnership or just your individual project. You can trust us to deliver you high-grade Headphone PCBs wherever you are. Whatever type of PCB or PCB assembly you need.

Call our sales team now!

Headphone PCB: The Ultimate FAQ Guide

Headphone PCB is the power center of headphones. Every electronic device has a printed circuit board inside them and headphones and so on. Headphone PCBs are widely used since the number of headphones is also increasing for their aspects.

You will need headphones for recreation, gaming, meeting, and so on. So the business demand is high in the headphone sector. Here comes the headphone PCB. We will elaborate on the headphone circuit board by answering some relatable questions.

What Is A Headphone PCB?

A printed circuit board or PCB is the powerhouse of the electronics from where power is generated to function the devices. Semiconductor components are used to power up the PCBs. PCBs generally own mechanical and electrical characteristics.

The PCB is used to power up and function the headphones is the headphone PCB. Headphone PCBs help the headphones to reproduce sounds. Headphone amp PCBs assist the headphones in amplifying the sounds, and the headphone jack PCB ensures the connection between the headphones and the sound-producing devices.

Headphone PCB

Most of the PCBs are made rigid, which is almost 90% of the whole PCBs. Also, there are flexible PCBs in the headphones too. There are wireless and Bluetooth headphones. Generally, headphone PCB, for instance, all PCBs use radio frequencies to operate the functionalities.

How To Make Headphone PCB?

Designing a headphone PCB needs some gradual steps to be followed. Proper design technology and efficient design is the key to the success of properly building a headphone PCB.

The following step-by-step tasks will drive you to complete a headphone PCB from the beginning to the end.

Determining Mounting Technology

Component mounting technology should be the first consideration of designing the headphone PCBs. It will help you to determine the following design steps. The way you want to mount the components in your headphone PCB is the component mounting technology.

Mainly, three mounting technologies are used in modern PCB design: surface mounting, through-hole, and press-fit technology.

Plan And Draw The Schematic Of The Headphone PCB

Now, draw the schematic of your headphone PCB. Schematic is the picture of a design that uses graphical symbols and shows where all components will be placed and how the circuits will be.

Designing The Layout

Design the PCB layout stack up, which comes from the schematic drawing you have drawn before. The layout design is the final visualization and will be printed on your headphone PCB board.

Every detail of the PCB must be contained in the PCB layout.

Printing The Layout On The Board

After successfully designing the PCB layout, now print the layout onto the headphone PCB board. Your PCB design will directly be visualized physically.

PCB Layout

Etching Traces

Now the time is to etch the conductive traces on the headphone PCB. The conductive traces will allow the current flow to pass across the PCB’s components. Keep the digital signal trace away from the analog signal traces.

Component Mounting

At this phase, mount the necessary components on the headphone PCB, including the mini speaker and other parts. Keep the high-frequency components away from the low-frequency components.

Use the predetermined component mounting technology to place the components correctly.

Board Coating And Fabrication

Fabricate and cover the PCB’s exposed copper area with protective material to prevent corrosion. PCB’s pads and conductive layers must be coated to keep the performance and physical structure flawless.

What Is Bluetooth Headphone PCB, And How Does It Work?

Bluetooth technology is a wireless technology that allows electronic devices to be connected. This technology is here to replace the cables that are used to connect the electronics.

The headphone that uses Bluetooth technology in the PCB is the Bluetooth headphone PCB. Bluetooth technology uses a wireless radio frequency to pass the signal from the transmitter to the receiver.

Working Principle Of Bluetooth Technology

The presence of an antenna on the Bluetooth headphone PCB is self-evident. The headphone PCB receives the signal and originates from Bluetooth devices such as cellphones, PCs, etc.

After the signal has been processed on the PCB, it is ready to sound through the headphones. Like other wireless technologies such as Wi-Fi, Bluetooth employs a radio frequency in the 2.4 gigahertz ISm range.

Bluetooth Headphone PCB

The star topology of the radio frequency is used to manage the Bluetooth devices. A master device and seven other Bluetooth devices can be synchronized at a time in a piconet. The associated devices are called slaves in this case.

The actual radio diverts in a piconet are shared by an assortment of synchronized devices to a similar clock and recurrence bouncing. The master device gives the gathering’s synchronization references.

Bluetooth headphone explanation is here:

What Are The Transmitter And Receiver In Bluetooth Headphone PCB?

Bluetooth Transmitter

Bluetooth is a technology that passes radio frequencies among electric devices and Bluetooth headphone PCBs. For example, when you listen to the sounds on your headphones, the signal comes from another circuit board, such as smartphones, computers, etc., to your headphone PCB. The devices that transmit the signal hold the Bluetooth transmitter.

The Bluetooth transmitter transmits the sensor data through wireless technology. Three significant components operate on the Bluetooth transmitter: sensor data, regulated voltage, and wireless transmission.

The controlled voltage powers the components and microcontrollers. The electrical function of the transmitter is the continuous voltage function.

Sensor data with a value ranging from 1 to 4 travels via the Bluetooth transmitter. It is dictated by the sensor, which is set off and afterward goes to the Bluetooth transmitter.

Bluetooth Receiver

While Bluetooth transmitters send the signal to your headphone, a receiver of the signal inside the headphone on the headphone PCB receives the signal to provide the output. Generally, a lithium-ion battery is used to power up the receiving device, and it is rechargeable.

Bluetooth Audio Receiver Circuit Board

The Bluetooth receiver on the headphone PCB holds an antenna to receive the radio frequencies from the Bluetooth devices. You can also find an auxiliary PCB on the receiver. It is an amplifier PCB that amplifies the sounds on the headphone.

What Are The Advantages And Limitations Of Bluetooth Headphone PCB?

Bluetooth technology makes electronic devices more feasible to use. The headphone is also among them with the Bluetooth Headphone PCB inside them. Numerous advantages might be countered for the Bluetooth headphone PCBs.

• Enable hands-free use of the smartphone while listening to the sounds
• Bluetooth is low-cost
• It is user friendly and automated
• Generates very low interference
• Bluetooth headphone PCB is reliable and universal
• Consumes low energy
• The most significant fact about the Bluetooth PCB is that it is wireless

Though the Bluetooth technology on headphones brings tremendous benefits, it also has some disadvantages too.

• The Bluetooth headphones can cause harm to your ears due to radiations
• Battery problem is common
• Less sound quality production than the wired ones

What Are The Differences Between Bluetooth And Wireless Technology In Headphone PCB?

Most of us may don’t know that Bluetooth and wireless technology have differences between them. Though all Bluetooth headphones are wireless, all wireless headphone PCBs don’t use Bluetooth.

With the following comparison, you would know the fundamental differences between the Bluetooth and wireless headphones PCBs.

Bluetooth Vs Wireless

• Where wireless headphones PCB uses radio frequencies and infrared to transmit the signals, Bluetooth headphones use only radio frequencies.
• Whereas the Bluetooth headphones can connect the devices between 30 feet, the wireless offers up to 300 feet of connectivity range.
• Wireless LAN is faster than the Bluetooth technology
• Wireless headphones usually require a wireless adapter, whereas Bluetooth has one in-built.
• Bluetooth headphones are easier to use than wireless ones.

What Is a Headphone Sound Amplifier PCB?

Before knowing the headphone amplifier PCB, knowing the amplifier would be better. A sound amplifier is an electronic amplifier that amplifies the low-power audio signals to the level of loud.

You will find sound amplifiers in any type of audio system, including headphone PCBs. Audio headphone amplifier PCB is the heart of the amplifiers containing the components used to amplify the sounds on the headphone PCBs.

Headphone Amplifier PCB

The components on the headphone amplifier PCB boost the signal intensity as it passes through the ICs, transistors, and mix tubes are driven by the power source. Soldering the components into the PCB substrate holds the parts in place on headphone amp PCBs.

Although the headphone amplifier PCB is a minor component, it comprises amplifying tubes, transistors, resistors, capacitors, integrated circuits (ICs), and input-output terminals. The O2 headphone amp PCB is an excellent amplifier sample that includes an anodized metal housing.

DIY headphone amplifier making:

How Does The Change Of Temperature Affect Headphone PCB?

Temperature is among the most critical states of headphone PCBs. Temperature plays different and significant roles on PCBs. So, avoiding the importance of temperature is impossible.

All you need to know is the role of different states of temperature on the PCBs. Then you can help the headphone PCBs material to comply with the temperature. Let’s elaborate on the temperature situation on the PCBs.

Glass Transition Temperature- Tg

Generally, the materials used in headphone PCBs, such as FR4 or others, soften when exposed to a specific temperature. The softened state becomes hardened when removing temperature from the PCB substrate.

The highest range of the temperature is known as the glass transition temperature of the PCB materials. The temperature ranges from 200 to 250 degrees Celsius. The effect of the Tg is temporary on the PCBs.

Decomposition Temperature- Td

When the headphone PCB’s substrate comes to a specific temperature, it decomposes. During the decomposition, the substrate loses around 5% of its total mass. The temperature that decomposes the substrate is called decomposition temperature.

Decomposition Temperature Effect

The effect of the decomposition temperature is permanent on the PCBs. So, the material should be able to handle such temperatures efficiently. Generally, the decomposition temperature capacity for the PCB substrate should be more than 250 degrees celsius.

Coefficient Of Thermal Expansion- CTE

The expansion rate of the headphone PCBs’ material is known as the coefficient of thermal expansion. When the PCB substrate is exposed to the temperature and goes behind the Tg, the CTE occurs.

The available range of the CTE is between 10 to 20 parts per million. 70 parts per million (ppm) could be the highest range of CTE. The less is temperature; the less is CTE. So, the materials should handle the temperature properly to maintain the average CTE range.

What Materials Are Used To Make A Headphone PCB?

PCB materials are the core element to form a PCB board. Headphone PCB boards consist of different types of material. A brief description is discussed below about the PCB core materials.

Prepreg

Prepreg is a thin glass fabric that is dried after coating with resins. The process happens through a prepreg treater machine. The glass in the prepreg is the mechanical substrate that holds the resin with it.

An epoxy resin such as FR4, Teflon, polyamide, etc., is coated with the glass by melting as a liquid. The substrates are melted at a temperature above 300 °F and then hardened. It becomes rigid and solid after getting hardened.

Copper Clad Laminate

Copper-clad laminate is made up of resin-coated prepreg sheets. The headphone PCB board is made up of many distinct types of copper clad laminate.

➢ FR4

In the PCB industry, FR4 is the most widely used NEMA-grade PCB material. It’s retardant. Mechanical, electrical, and thermal qualities are all excellent. When it comes to building PCB boards, FR4 is quite dependable.

FR4 Laminate

➢ Polyamide

Polyamide laminate offers more higher-temperature adoptability than FR4 material. It has more thermal, electrical, and mechanical compatibility than FR4 and is more expensive.

➢ Teflon Laminate

Teflon laminate also offers more stability in mechanical, electrical, and thermal performance. It is also more expensive than the previous two materials. Teflon materials can be covered in glass fabric to increment mechanical characteristics.

➢ Flexible Laminate

Flexible laminates can be bent and offer folding features to PCBs.

➢ Copper Foil

Copper foil is the element we etch on the headphone PCB to make conductive traces on the laminate. It becomes the conductive layers inside and outside of the PCB layers.

What Are The Testing Methods Of Headphone PCB?

With proper testing methods, your headphone PCB will be finalized for launching in the market. Faulty PCBs would lead you to loss of the business. That is why testing is essential to ensure the functionality of the PCBs.

There are different types of testing methods available. Here we discuss the most used three types of PCB testing methods.

In-Circuit Test (ICT)

N-circuit testing is the most popular PCB testing method. The test powers up the testing with every individual circuit and tests them. The testing method is designed for 100% accuracy, though you will get almost 85-90% accuracy. ICT is also known as the bed-of-nails test.

Automated Optical Inspection (AOI)

In the AOI testing, either a 2D or two 3D cameras are used to take different angle photos of the circuits of the headphone PCBs. The taken photos are then compared to the schematic of the PCB you designed at the first step of the PCB design.

2D And 3D AOI

If any mismatch is found, the board goes under a technician to check the board for further action and resolve the issues. AOI testing collaborates with other testing methods too.

X-Ray Inspection

X-ray inspection helps to find out the internal and critical faults more efficiently. It’s an early defect testing that finds the fault before manufacturing. X-rays are passed through the solder connections, internal traces, and barrels to find out any fault if it exists.

Why Is Impedance Control Vital For Headphone PCB?

During the high-frequency passing, the signal passing goes through the stable combination of capacitance and inductance. This combination of stability is known as impedance. Impedance is measured into ohms.

The continuous passing of the signal makes the PCB deal with signal integrity problems. S, the signals must be considered as transmission lines, and impedance control is needed here.

Controlled Impedance Is Important For Flawless Signals

The PCB traces will not be in their natural state at higher frequencies. Controlled impedance prevents signal degradation and maintains signal integrity within the anticipated range.

Controlled impedance is utilized when a signal must perform adequately. Impedance control is required to guarantee data integrity and signal clarity. The high-frequency signal will be downgraded to pass if extra attention is not given during PCB design, and the switching time will be increased. It’s also possible that random mistakes will occur.

What Is Component Mounting Technology In Headphone PCB?

Component mounting technology is the process of mounting components on the headphone PCBs. This defines how you place the components and fit them. There are three component mounting technologies: Through-Hole technology, Surface Mounting Technology, and Press-Fit Technology.

Through-Hole Technology

In the through-hole PCB assembly technology, drilling the headphone PCB board is needed. After drilling, the components will be placed and soldered.

Surface Mounting Process (SMT)

In the Surface Mounting Process, the components are placed on the surface and soldered with the pads instead of drilling the PCB board. Most of the PCBs in the modern era use SMT technology to assemble the components.

Surface Mounting Idea At A Glance

Press-Fit Technology

In the Press-Fit technology, the components are placed onto the boards by pressing the components on the panel through a press-fit connector and press-fit pins.

How Could You Control The Overheating Issue Of Headphone PCB?

Overheating will cause fatal damage to your PCB if it is not controlled. You can prevent overheating issues by following the steps below.

• You could use a heatsink. Heatsink will consume the overheat produced in the components.

Heatsink On PCB

• The cooling fan would be another great option
• Use thick PCB board
• Apply proper coating and lamination to keep the temperature low.

What Is The Importance Of Electrical Property Stability In Headphone PCB?

Different electrical properties of the headphone PCB material should be in the proper range to ensure the electrical performance of PCBs. Dielectric constant (Er), dielectric loss tangent (tan δ), volume resistivity (ρ), and surface resistivity are the electrical properties of the PCB materials.

The dielectric constant range is generally from 3.5 to 5.5. The less the Er is; the more performance is performed. The typical tan δ is generally in between 0.02 to 0.001. For getting proper analog signals, tan δ plays a vital role.

Dielectric Constant And Loss Tangent Graph

The volume resistivity should be high to act as a high dielectric insulator. The range should be 10^3 to 10^10 Megaohm-centimeters. Also, the surface resistivity should be increased, with the range of 10^3 to 10^9  cMegaohms per square.

Resisting electrical breakdown is known as electrical strength. This should be between 800 V/mil to 1500 V/mil.

What Are The Types Of Headphone PCB?

In terms of the manufacturing process, different types of headphone PCBs are there. Following are the different types of headphone PCBs.

• Single-sided PCB: Most common PCB with a single conductive layer.
• Double-sided PCB: A double-sided board is formed with a thin layer of conductive material on both sides of the PCBs. Holes on the board allow connecting both sides.
• Multilayer PCB: With more than two copper layers, a multilayer headphone PCB is formed. At least three or more conductive layers are used. All layers are pressed and heated to join together.
• Rigid PCB: Rigid boards are that strong that cannot be bent or folded. Rigid PCB substrate gives rigidity and strength to the board.
• Flexible PCB: Flexible PCBs are made of flexible PCB base substrate. Flexible PCBs can be bent or folded.
• Rigid-Flex PCB: Rigid-Flex PCBs are a mixture of rigid and flexible PCBs.

Rigid-Flex Headphone PCB

How Can You Shield The Headphone PCB Against Electromagnetic Interference?

Electromagnetic interference can be costly and dangerous for headphone PCBs. It can destroy the components of the PCBs. So, EMI shielding is vital on PCBs. You could follow the following suggestion to shield the PCBs.

• Properly ground the board.
• Keep analog and digital signals separate.
• Shorten the ground return paths
• Use vias properly
• Keep separating the low-speed and high-speed parts
• Shield the components with Faraday Cage, a thick protective enclosure.
• Shielding the cables helps to reduce the EMI, though the wires produce EMI issues.

Which Facts Should You Consider To Make A Quality Headphone PCB?

To ensure designing a quality headphone PCB, you should consider a few facts before creating the board. Otherwise, the whole design could go wrong or not be that efficient.

• Plan the design before drawing the schematic
• Efficiently design the layout
• Use high-grade materials to form the PCB board
• Select the efficient components
• Place the components based on the proper alignment
• Ensure the well managed and adequately decorated workplace
• Ensure the PCB testing before and during manufacturing
• Ensure proper grounding
• Ensure appropriate coating to prevent corrosion
• Keep proper space among the traces

PCB Tracing

What Are The Limitations Of Headphone PCB?

The radiation of the headphone PCBs can harm our physical and mental health in many ways. The following phenomenon could happen with the inefficient design of headphone PCBs and excessive use of headphones.

• Noise-induced hearing loss
• Ear infection
• Excessive ear wax
• Hypertension
• Ear pain
• Affect on the brain
• consequence s may happen in the hair cells called Tinnitus
• Extreme pressure in the ear could cause dizziness, and so on.

How Can You Find A Reliable Headphone PCB Manufacturer?

While you will manufacture bulk headphone PCBs, finding a reliable and skilled manufacturer should be your priority. You should carefully choose your headphone PCB manufacturer with the following criteria.

• Sufficient industry experience
• IPC certified manufacturer
• Fast and reliable customer services
• Extensive and quality work area
• Bulk production capability
• Deadline meeting ability
• Cost-efficiency, etc.

These features on a headphone PCB manufacturer could make them a reliable and great manufacturer.

Conclusion

Headphone PCBs are among the most used PCBs in the PCB because of excessive use of headphones for many aspects. So, to catch the headphone market, you have to ensure the quality headphone PCBs inside the headphones.

PCBMay is one of the leading headphone PCB manufacturers to ensure top-notch quality PCB making for their clients. Contact us today to get your desired services.