Your Trustworthy High Current PCB Manufacturer

PCBMay- Your Professional High Current PCB Manufacturer and Supplier in China

PCBMay is your best source for High Current PCBs. Since 2008, we have been a reputable High Current PCB maker. We are also active in distribution not just in China but in all major markets across the world.

PCBMay manufactures high-quality High Current PCBs. Because we have skilled engineers and a technical team that have been with us for over two decades, we can ensure the finest quality. We guarantee that you will receive the most high-performing High Current PCBs and related items.

PCBMay offers a wide range of High Current PCBs. We have all sorts of High Current PCB products, sizes, and designs. Our High Current PCB carries unique properties that make it suitable for several commercial and industrial applications. We can customize the PCB product line to meet your particular need. You will be able to take full advantage and benefits when you utilize our High Current PCB.

We ship PCBMay High Current PCBs all over the world. We get good reviews from our customers, both new and old. They are always impressed with our craftsmanship. We have the adequate design staff to guarantee that you get a fantastic product.

Our High Current PCB is always ISO, UL, and RoHS approved. To assure your trust, we always uphold our industry reputation. We will gladly meet your High Current PCB requirements. We are familiar with printed circuit boards and all electronic components as a competent supplier.

As a profitable manufacturer in the PCB business, we can deliver your High Current PCB to any country. We can deal with the layout and outline of your PCB. We promise that we will meet your High Current PCB standards and that you will obtain the items as desired. Furthermore, we always create precise and damage-free High Current PCB.

PCBMay will never let you down and we will always meet your needs. We are eager to work with you and support the growth of your business. Please feel free to contact us if you require any further information!

High Current PCB: The Ultimate FAQ Guide

Are you looking for a hardy type of circuit to handle heavier current loads?

Then, a High Current PCB is the perfect solution to meet your demand. This PCB contains effective elements that develop the current conduction capacity of electronic devices. Do you know about its manufacturing details?

PCBMay is the leading supplier and designer of High Current PCBs in China. Through this guide, we aim to provide worthwhile information about the manufacturing, features, and applications of this type of circuit board  It will definitely give you significant updates about High Current PCBs.

Let’s begin.

What Is a High Current PCB?

High Current PCBs have brought a great change in the electronics world. This circuit board is used in applications dealing with a much higher flow of electricity compared to other circuits.

Usually, a High Current PCB contain thick copper on the surface along with dielectric materials. Its dimensional stability is strong. So, this PCB’s trace width is supportive of the level of impedance control which significantly promotes current conduction.

The High Current PCB can manage via placement in different layers. As a result, the flow of electrons and thermal energy increases efficiently.

High Current PCB

The components and technologies used in the High Current PCB’s operation are supremely effective in tolerating high electrical forces. That’s why a high current PCB is capable of providing long life performance of devices.

How to Handle High Current  Loads on PCBs?

When a PCB deals with higher current loads, you need to take some precautions to avoid overheating and other thermal-related issues. Here, we are going to explain some factors required to handle high currents and power on circuit boards.

Trace Width

Effective use of PCB trace width is important to carry large current loads. Usually, High Current PCB traces have short widths. This results in the right conditions allowing low current resistance.

Copper Thickness

The copper thickness of circuit boards affects the trace width. Thick copper boards are supportive of short trace width which results in promoting current carrying capacity.

Thermal Management

High Current circuit boards contain some sensitive components. Examples of these are amplifiers, regulators, converters, and voltage references. Extreme temperature causes the malfunction of these PCB components.

That’s why you should separate these elements to reduce thermal effects. Aside from this, proper via placement plays a significant role in dissipating high heat.

For example, thermal vias are used in conducting heat away from temperature-sensitive components. Thus, a High Current PCB is capable of handling thermal effects caused by carrying higher current loads.

Elimination of Solder Mask

Eliminating solder masks from the PCB is an effective way to increase copper thickness. It leads to low trace width and increased resistance in current-conducting PCB components.

Eliminating the solder mask can ensure good functionality and longer operating life. Again, you don’t need to alter the trace width for increasing current-carrying capacity if you eliminate solder masks.

Handling High Current Loads In PCB

Component Mounting

Component placement with proper mounting improves the ability to handle high current loads in PCB. You must avoid placing thermally isolated components near the edge. It promotes heat accumulation in the PCB border.

High current components need to be placed on the PCB surface by maintaining a proper distance. The correct placement enables the circuit board to distribute heat without causing any serious damage.

If you place all of these components in a specific region, this creates heat concentration in this PCB. Be sure to mount microcontrollers near the priory integrated circuit.

Polygon Pours

The use of polygon pours is useful in separating thermally vulnerable PCB components. Polygon pours are applied to the circuit board through the PCB.

These are the most perfect ways to handle the high flow of electricity in a PCB. You need to consult with a reliable manufacturer to design a PCB concerning your needs.

How to Measure the Highest Current Carrying Capacity of a PCB?

A High Current PCB is maximally effective in carrying heavy current loads. Its capacity of current conduction depends on some factors, however. Such factors include temperature, trace width, copper thickness, etc.

It is easy to measure the highest current-carrying capacity of a circuit board. You can apply the following formula in this case.

Current-capacity Formula

Here, a and b are 0.725 and 0.44 respectively. K is a constant that depends on the PCB layers. Its value is variably related to the outer and internal layers. Whereas, the T rise indicates the change of temperature. The copper thickness and temperature rise are determined based on IPC 2152 standard.

PCB High Current Conduction

How Much Current Can a High Current PCB Via Handle?

The use of PCB vias is an effective process to distribute heat in different layers of a circuit board.  High current PCB vias handle the thermal distribution and flow of electricity.

Usually, a PCB of 200 mils trace width and 45⁰C trace temperature can handle almost 8-10A current.

Its highest current rating depends on some dimensional properties. Via size is one of them. This aspect is related to the PCB trace dimensions You also need to consider that temperature change affects the current flow in a PCB via.

PCB Via Maximum Current-Carrying Capacity

A PCB that is supportive of high current flow contains dielectric materials such as FR4 and CEM. These materials provide impressive thermal conductivity to different PCB layers. They act as heat sinks for the conductors.

This is one of the top reasons why the PCB vias’ operating temperature is lower than the trace temperature. Watch this video for further explanation:

What Are the Advantages of High Current PCBs?

The most notable advantages of high current PCB are:

• Components are tolerant to extreme temperatures because of superior thermal management.
• Delivers the highest degree of freedom to electronic appliances
• Design is supportive of the SMD assembling process: enables designers to do miniature devices
• Compatible with a wide range of electronic applications
• Operating temperature is sufficiently high
• Contains effective dielectric materials that ensure high insulation in PCB projects
• High current PCB connectors provide impressive mechanical strength.
• Highly reliable in high-frequency projects

Highly Functional High Current PCB

How Does Trace Width Affect the Current Conduction in a High Current PCB?

PCB trace width affects electrical conduction in different ways. Some of its significant contributions in a high current PCBs are:

• Trace width influences the current carrying capacity of PCB via. Short trace widths can operate similarly as a heat sink for vias.
• Trace width has a great impact on impedance. Well-calculated trace width is effective for ensuring impedance stability during signal transmission.
• Maximum current conduction in PCB relies on the cross-sectional area that is directly proportional to the trace thickness.
• Power traces are associated with polygon pours that play a significant role to separate vulnerable components. Proper trace width ensures the optimization of using polygon pours.

High Current PCB Trace Width

Another thing to note is that trace width affects copper thickness and metallic coating. These are useful in restricting chemical contamination. When these additional factors are considered, current conduction in a PCB increases.

Where Do You Use a High Current PCB?

A High Current PCB has countless uses in several commercial sectors. Its superlative current management and functionality make this type of circuit board compatible with digital devices. Most significantly for:

• Transformer
• Motherboard
• Adaptor
• Electric car
• Solar inverter
• TV
• Telecommunication devices
• Advanced gaming consoles
• Military equipment
• Medical Instruments
• Aerospace gear
• Defence industry
• Wireless communication
• Smart Home appliances

High Current PCB Application

How Do Polygon Pours Improve the Current Conduction Capacity in a PCB?

Polygon pours improve the current conduction capacity of printed circuit boards in many ways. Polygons are usually used in creating a solid portion inside a PCB layer. Also, polygon pours reduce the irregularity of PCB shape. This is highly important for current conduction.

Polygon pours are connected to the power trace of the circuit board through the PCB vias. The pours are normally located beneath the chip, with a zone indicated for carrying larger current loads.

Polygon Pours in High Current PCB Design

Using these polygons in a high current PCB design is tricky. What you can do is set apart the PCB components which don’t have a high tolerance against temperature by applying polygon pours. This step is applicable in single-layer PCB design, broadly.

Which Copper Thickness Is Appropriate for High Current PCB?

Thick copper PCBs like 6 oz., 10 oz., etc. are appropriate for high current PCB design. Standard 1 oz. copper PCB or other circuit boards having lower copper thickness can’t handle high current loads.

Copper thickness is associated with trace width which improves current conduction. That’s why you need to use a heavy copper surface to ensure PCB trace max current. Thick copper is expensive compared to circuit boards with thinner copper.

Heavy Copper Thickness in PCBs

In that case, you need to think of a trade-off between current conduction and cost-effectivity. You can optimize copper thickness through utilizing design software.

What Are the Common Problems of High Current PCBs?

Improper high current PCB design cause problems in electronic appliances. You must consider potential adverse effects or mistakes in design while incorporating a High Current PCB connector in the design layout. Major sources of problems are:

Overheating

Overheating is the most common problem in the PCB world. High current-conducting circuit boards suffer from overheating if traces and planes are not well-designed. During overheating, components operate at higher temperatures compared to their normal levels.

When most PCB components are subject to extreme temperatures, they start operating deficiently.

Low Functionality

High current loads cause the melting down of the PCB materials in some cases. Too high a current load decreases the functionality of a circuit board. Besides, the PCB malfunctions due to improper thermal management too.

Lack of Reliability

Short trace widths are necessary to promote electron flow. But, short trace widths can turn traces into dangerous electrical parts. In some cases, traces can burn in a similar way to a blown fuse. All of these indicate a less reliable electric circuit.

High Current PCB Problems

PCBMay supplies different types of High-current Printed Circuit Boards at reasonable prices. Our products are made of quality materials that ensure superior functionality along with a longer shelf life. Inquire with us today to experience the best PCB manufacturer to handle your high current applications.

How Do You Control Impedance in High Current PCB Design?

Impedance control is a vital issue for a high current PCB. Sound impedance control improves the electrical and mechanical properties of PCB materials. You need to consider some factors to ensure impedance stability.

Dielectric Thickness

Low dielectric thickness is required for controlling impedance in a high current circuit board. It has a logarithmic relation with impedance.  You really need to maintain the moderate thickness of insulating materials in this case.

Trace Width

Trace width has an inverse relation with impedance control of a PCB. Higher width ensures PCB trace max current. You should use the correct trace width after factoring in temperature and copper thickness.

Copper Thickness

High copper thickness is useful to achieve low impedance. It is required to use a thick copper PCB to control impedance. This will result in higher current transfer in the PCB layers.

PCB Impedance Control

Dielectric Constant

Considered a major influential factor in the PCB world, the dielectric constant or relative permittivity indicates the charge density in an electric substance. A low Dialectric Constant is mandatory for maintaining the dielectric properties in a PCB.

Besides, PCB materials with a low dielectric constant are compatible with high-frequency signal transmission. These types of materials promote insulating properties to ensure impedance matching in different PCB layers.

What Is the Effect of Using Busbar on High Current PCBs?

Busbars have significant effects in developing High Current PCB performance. Busbar use is widely seen in the automotive industry, as well as aerospace. The equipment in these sectors handles higher current loads. Hence, you can apply copper busbars as an alternative to heavy copper surfaces.

High Current PCB Busbar

Another reason why busbars can be used is that busbars improve the functionality of the heat sink. They also promote the thermal distribution in  Multilayer PCB designs. Most noteworthy of all reasons, PCB busbars allow the designer to create a PCB with an optimum degree of freedom.

How to Create a High Current Busbar on a PCB?

High current PCB busbars are useful for customized power applications. You can follow the instructions given below to create a busbar on a circuit board.

• Use thicker PCB traces along with thick solder coating.
• Solderable wires need to be made of thick copper.
• Use solderable screws at the busbar of a high current PCB terminal.
• Apply a wide and thick copper plane to optimize the high current busbar.

Busbar Connectors Used in a PCB

Following these recommendations result in a less expensive and effective busbar on High Current PCBs.

What is the Iceberg Principle of High Current PCBs?

The iceberg principle is related to the copper thickness of inner PCB layers. It is used in creating a uniform surface throughout the high current PCB connectors. Usually, the copper thickness of around 450 um is useful for achieving a planner PCB surface.

Iceberg structures are appropriate for power components because of their functionality as heat sinks. Besides, they are compatible with plated through-holes that improve the high current PCB thermal management.

How Can You Calculate Trace Width in High Current PCB?

Trace width plays a vital role in developing the current conduction capacity of the high current PCB terminal. You can easily calculate the PCB trace width by using this equation:

Here, A and T indicate the cross-sectional area and trace thickness respectively. You should apply the correct trace width to optimize the PCB performance. This formula is also related to temperature rise and copper thickness.

High Current PCB Trace Width Calculation

Tip: It will be helpful to use design software to calculate the required trace dimension concerning your project.

What Are The Properties of a Reliable High Current PCB Manufacturer?

Choosing a reliable manufacturer is a crucial part of PCB development. A High Current PCB is no different in this case. you should look for a reliable PCB manufacturer considering important factors such as:

Manufacturing Experience

An experienced manufacturer can deliver a hassle-free manufacturing service. Solid experience is important when finding minute complications that are ignored by a manufacturer who lacks assembly knowledge. You should give top-most priority to years of manufacturing experience when considering your options.

High-Quality Products  

Product quality is another vital issue for a High Current PCB manufacturer. A good manufacturer should have the ability to produce IPC class 3 standard PCBs. Again, RoHS certification indicates sound standard quality for circuit board fabrication.

You have to verify certifications as well as the material quality of your PCB manufacturer. to be safe.

High Current PCB Manufacturing

Affordable Cost

A trustworthy manufacturer will provide different types of PCBs at affordable costs. You can compare the product price with the competitors to get ideas about the average cost.

Skilled Technical Staff

A group of skilled and professional technical staff is a reliable indicator of high-quality PCB manufacturers. If the technicians are ISO certified, you can be sure about their skill and quality.

Customer Service

Full-time customer care and sales services are very important. A high current PCB manufacturer should have an up-to-date website where you can get the essential information about PCBs.

Custom Solutions

Your selected PCB supplier should have the capabilities of rendering one-stop custom solutions according to your design. You must ensure this thing before choosing the manufacturer.

These are the major considerations when finding a dependable High Current PCB manufacturer in China. PCBMay manufactures IPC class 2 and class 3 standard PCBs which can carry high current loads.

We have a well-structured factory along with high-profile technicians to customize PCBs according to your requirements. So, contact us to enjoy the best manufacturing service while maintaining your budget.

What is the Maximum Power Rating of a High Current PCB?

The maximum power rating of a high current PCB relies on its voltage supply, temperature rise, etc. You can find out this rating by applying this formula:

Power rating, P = Current (I) Voltage rating (V)

High Power PCB Via Stitching

Since High Current PCBs can handle extreme electron flow, there is a large amount of power dissipated. Its superior impedance control and resistance to electrical strength enable this PCB to deal with high power ratings.

Which Factors Need to Be Considered While Designing a High Current PCB Layout?

The following factors are supremely considerable for High Current PCB design.

Metallic Conductors

Using metallic conductors is an effective way to route power connections in a PCB. Metallic conductors help the handling capability of PCB traces and vias. Another tip: avoid using ground traces for the routing.

Instead, you can apply a full plane in this case. Metal conductors promote the integrity of high-power PCBs.

Component Placement

You need to give topmost priority to component placement in a High Current PCB design. For example, the components used in high-speed data transmission should be kept away from high-current components. In addition, make sure you these circuitries are grounded properly.

High-power components require a short path for current transmission. You should also place them close to their connected parts. To do this, you can apply a high current PCB connector to establish a secure connection.

PCB Drill Holes

If you intend to make your PCB capable of carrying higher current loads, you must apply multiple holes on the PCB surface. Again, a wider hole size is appropriate for better current conduction.

In addition, you can use a thick copper surface on the board. It supports the smooth use of drilling bits on the circuit board.

High Current PCB Design Technique

Thermal Distribution

High-power parts should be placed in the PCB centre. This enables better heat dissipation and isolation from temperature-sensitive components. The use of a high current PCB jumper and shunt create another current path to carry extra electrons.

You can think about including thermal vias, heat sinks to the circuit board for achieving better thermal management. It is necessary to use dielectric materials to achieve a low coefficient of thermal expansion.

Lastly, you need to follow IPC 2152 standard to apply the best trace width, temperature, hole diameter, and etc. for PCB designs. There are many design software available like Altium Designer, KiCAD which are reliable for high current PCB designs.

Watch this video to learn more about high current PCB design:

Conclusion

High Current PCBs promote the durability of your electronic appliances significantly. Outstanding functionality and easy maintenance make this PCB a trusted circuit solution nowadays.

PCBMay has been delivering effective assembly service of High Current PCBs for an extensive amount of time. This FAQ guide has covered almost every aspect of PCBs handling heavier current loads. If you face any difficulty with its manufacturing, feel free to contact us immediately.