High Voltage PCB Design, High Voltage PCB Design Suppliers

Table of Contents

Ever wondered how high voltage PCB design ensures safety and performance? This guide covers rules, supplier selection, and real-world case studies for industrial applications.

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What Is High Voltage PCB Design?

High voltage PCB design is a specialized area of printed circuit board development that deals with the creation of boards capable of handling elevated electrical potentials. These boards are integral to various systems where standard voltage levels won’t suffice, such as in power transmission equipment, industrial machinery, and certain medical devices. Compared to standard FR4 PCB design, high voltage PCB design demands increased insulation (e.g., thicker solder masks, higher-quality FR4 materials), wider component spacing to prevent arcing, and careful selection of materials with higher dielectric strength to ensure safe, reliable operation under high voltage conditions.

What Are Rules in High Voltage PCB Designs?

Clearance Requirements: Guarantee an adequate distance between conductive traces, vias, and components. This spacing is determined by the operating voltage and environmental conditions. For example, higher voltages necessitate greater separation to prevent arcing and electrical breakdown.
Insulation Material Selection: Select appropriate insulation materials with high dielectric strength. Materials such as FR – 4 with enhanced dielectric properties can provide better protection against electrical leakage.
Trace Width and Thickness: Design traces with sufficient width and thickness to handle the high current in high – voltage applications. Thicker traces reduce resistance and minimize heat generation.
Ground Plane Design: Create a robust ground plane to serve as a stable reference point and reduce electromagnetic interference. A well – designed ground plane effectively dissipates electrical noise.
Component Placement: Arrange high – voltage components to minimize the risk of electrical stress on other components. Avoid placing sensitive components close to high – voltage sources.
Testing and Verification: Implement comprehensive testing procedures, including high – voltage testing, to ensure that the PCB meets the required safety and performance standards.

High Voltage PCB Design Guidelines

Below are guidelines about how to design high voltage PCB:

Understand the Application Requirements

Voltage Range: Begin by determining the exact voltage levels the PCB will handle, including peak and continuous voltages. For example, if it’s for a power supply application that needs to step up from 12V to 500V, account for transient spikes that might reach 600V or more. Measure the voltage tolerance of each component and ensure the PCB layout can handle these levels without arcing or breakdown.
Current Capacity: Calculate the maximum current the circuit will carry. This impacts the width of traces; thicker traces are required for higher currents to reduce resistance and prevent overheating. Use the IPC-2152 standard to calculate the minimum trace width based on the current and temperature rise requirements.
Environmental Factors: Consider the operating environment. In a high – humidity setting, use conformal coatings to protect against moisture – induced corrosion. In a high – altitude application, account for the reduced air density, which can lower the breakdown voltage of air gaps, and increase the spacing between high – voltage components accordingly.

Follow Industry Standards

IEC Standards: For example, IEC 60664 – 1 defines the insulation coordination for equipment within low – voltage systems. When designing a high – voltage PCB, ensure that the insulation distances between live parts and the creepage and clearance distances meet the requirements specified in this standard. This includes maintaining appropriate distances between traces, vias, and components to prevent electrical breakdown.
UL Regulations: UL 1950, for information technology equipment, sets safety requirements. Adhere to these when designing PCBs for devices like servers or data centers with high – voltage power supplies. Test the PCB for compliance with UL’s safety requirements, such as flammability resistance of materials used.

Use Simulation Tools

Software Selection: Popular circuit simulation tools like PSpice or Saber can be used. For high – voltage PCB design, these tools can model the behavior of components under different voltage and current conditions. For example, simulate the performance of a high – voltage capacitor in a resonant circuit to check for voltage spikes and ensure its safe operation.
Fault Simulation: Run simulations to mimic potential faults, such as a short – circuit between two high – voltage traces. Analyze how the circuit responds and whether it can withstand the fault without causing a catastrophic failure. Use the simulation results to modify the design, such as adding additional protection components or adjusting trace routing.

Consider Thermal Management

Heat Sink Design: Select a heat sink with an appropriate thermal resistance based on the power dissipation of the high – voltage components. Calculate the power dissipated in components like high – voltage transistors using the formula P=VI, where V is the voltage across the component and I is the current through it. Ensure proper thermal interface materials, such as thermal paste or pads, are used to improve heat transfer between the component and the heat sink.
Thermal Vias: Incorporate thermal vias in the PCB layout. These vias connect different layers of the PCB, allowing heat to be conducted away from high – power components more effectively. Place thermal vias in a grid pattern around the component to evenly distribute the heat across the PCB layers.

Design for EMC Compatibility

Shielding: Use conductive shielding materials, such as copper or aluminum foils, to enclose sensitive high – voltage components or sections of the PCB. Connect the shielding to the ground plane at multiple points to ensure effective grounding. For example, shield a high – frequency oscillator on the high – voltage PCB to prevent its electromagnetic emissions from interfering with other parts of the circuit.
Grounding Techniques: Establish a solid ground plane. Use star – grounding for sensitive circuits to minimize ground loops and reduce electromagnetic interference. Connect all high – voltage return paths to the ground plane in a controlled manner, ensuring that the ground impedance is kept low.

Documentation

Component Specifications: Document the detailed specifications of each component used, including the manufacturer, part number, voltage rating, current rating, and any other relevant characteristics. This information is crucial for component replacement and ensuring the continued safety and performance of the PCB.
Design Calculations: Record all design calculations, such as trace width calculations, insulation distance calculations, and power dissipation calculations. This allows for easy verification of the design and provides a basis for future modifications.
Test Results: Keep a record of all tests performed on the PCB, including electrical tests (such as voltage withstand tests, insulation resistance tests), thermal tests, and EMC tests. Note any failures and the corrective actions taken.

Iterative Design Process

Testing Phases: Conduct multiple rounds of testing, starting with bench – top testing of individual components and sub – circuits, followed by full – system testing. Analyze the test results carefully, looking for any signs of component failure, performance degradation, or safety issues.
Feedback Incorporation: Based on the test results and feedback from other engineers or end – users, make iterative changes to the design. This could involve modifying the component layout, changing component values, or adjusting the thermal management or EMC – related design features. Continuously repeat the testing process after each iteration until the high – voltage PCB meets all the design requirements.

High Voltage PCB Design Considerations

Select suitable high-voltage components: give priority to electronic components with rated voltages that meet high-voltage working conditions to avoid device failure due to voltage overload, such as high-voltage ceramic capacitors, high-voltage MOSFETs, etc.
Reasonable derating: design high-voltage components with derating, such as controlling the operating voltage of components to 60%-80% of the rated voltage to cope with voltage surges and fluctuations and improve long-term stability.
Strictly control welding process: use high-reliability welding technology (such as wave soldering, reflow soldering) to ensure that the solder joints are full and there is no virtual solder joints, and prevent local overheating or arcing due to poor contact.
Optimize line layout: accurately plan the routing, maintain sufficient line spacing (recommended ≥2mm/kV), avoid parasitic capacitance caused by parallel long routing, and physically isolate high-voltage lines from low-voltage lines.
Strengthen insulation design: select PCB substrates with high insulation performance (such as FR-4 high TG materials), increase the thickness of the insulation layer, spray three-proof paint or add insulating potting glue when necessary.
Reserve heat dissipation space: For components that are prone to heat under high voltage (such as power resistors and IGBT modules), design heat dissipation copper foil or install heat sinks to ensure that the operating temperature is lower than the critical value of the components.
Consider environmental factors: In high humidity environments, use moisture-proof coatings; when dealing with temperature fluctuations, choose materials with low temperature coefficients to prevent thermal stress from causing PCB cracking.
Perform test verification: After the design is completed, perform voltage withstand tests (such as 1.5 times the rated voltage), insulation resistance tests, and environmental aging tests to ensure compliance with safety standards.

What Are Common Issues of High Voltage Power Supply PCB Design?

Electrical Breakdown

Cause: Insulation failure between conductive elements due to insufficient clearance (e.g., less than the recommended 5mm for high voltage), low – quality insulation materials, or high humidity.
Solution: Maintain a minimum clearance of 5 – 10mm between high – voltage traces and components, and use FR – 4 materials with a dielectric strength of at least 14 kV/mm.

Overheating

Cause: Narrow traces (less than 0.5mm width for high – current paths) and inadequate cooling.
Solution: Use traces with a width of 1 – 2mm for high – current paths, install aluminum heat sinks with a thermal resistance of ≤2.5°C/W, and increase the number of thermal vias to 10 – 15 per square inch.

Electromagnetic Interference (EMI)

Solution: Encase the PCB in a metal shield with a conductivity of at least 50% IACS, implement a star – grounding system, and insert ferrite bead filters at the power input.

Component Failure

Solution: Select components with a voltage rating 1.5 – 2 times the operating voltage and a current rating 2 – 3 times the maximum load current. Use reflow soldering with a peak temperature of 245 – 255°C for proper joint formation.

Leakage Current

Solution: Employ PTFE – coated substrates with a leakage current density of <1μA/cm² and ensure all insulation layers have a thickness of at least 0.2mm.

Voltage Spikes

Solution: Place metal – oxide varistors (MOVs) with a clamping voltage 1.2 – 1.3 times the rated voltage at the power input and output of the PCB.

Insulation Degradation

Solution: Use silicone – based conformal coatings with a dielectric strength of 20 – 25 kV/mm and inspect the PCB for signs of insulation damage every 6 – 12 months.

Poor Signal Integrity

Solution: Route high – speed signals on inner layers with a 50 – ohm impedance, use series – terminating resistors (22 – 33Ω) at the source end of the traces, and add buffer amplifiers for long signal paths.

Inadequate Grounding

Solution: Design a solid ground plane covering at least 80% of the PCB area, and use multiple vias (3 – 5 per connection) to connect different ground layers.

Thermal Expansion and Contraction

Solution: Use PCBs made of polyimide materials with a coefficient of thermal expansion (CTE) of 15 – 20 ppm/°C and choose components with a similar CTE range.

How to Choose High Voltage PCB Design Suppliers?

Here are methods about how to choose high voltage PCB design suppliers:

Experience and Expertise

Prioritize suppliers with at least 3 – 5 years of dedicated high voltage PCB design experience. Review their portfolio for projects similar in voltage rating (e.g., >1000V), complexity, and application (such as power electronics or high – energy physics). Request case studies demonstrating how they resolved design challenges like creepage and clearance issues.

Technical Capabilities

Confirm that suppliers use industry – standard design tools like Altium Designer with high voltage design libraries. Their manufacturing processes should support high – precision techniques, such as controlled impedance routing and multi – layer PCB fabrication. Ask for details on their testing facilities, including the availability of high voltage testers and thermal cycling chambers.

Quality Assurance

Verify that suppliers follow ISO 9001 quality management systems. They should provide detailed inspection reports for each production batch, including visual inspection, X – ray inspection for internal connections, and functional testing results. Ensure they can offer certificates of compliance with relevant high voltage standards, such as IEC 60664 for electrical insulation coordination.

Cost – Effectiveness

Obtain quotes from a minimum of 3 suppliers, comparing not only the unit price but also the overall cost structure. Consider factors like tooling costs, setup fees, and potential volume discounts. Evaluate the cost – to – performance ratio by assessing the quality of materials used (e.g., high – voltage – rated laminates) and the expected lifespan of the PCBs.

Delivery Time

Select suppliers who can provide a detailed production schedule at the quotation stage, breaking down the time for design review, fabrication, assembly, and testing. Look for a lead time that aligns with your project timeline, with a buffer of at least 10 – 15% to account for potential delays. Confirm their ability to expedite orders if necessary, and inquire about any associated rush fees.

Customer Support

Choose suppliers with a dedicated project manager for high voltage PCB design. They should offer 24/7 emergency support channels for critical issues and provide regular progress updates during the design and manufacturing process. Check if they have a technical support team capable of assisting with design optimizations and troubleshooting post – production.

Reputation

Research suppliers on industry – specific platforms like PCB Directory or EIPC. Read reviews from clients who have worked on high voltage projects, paying attention to feedback on design accuracy, communication, and problem – solving. Request references and directly contact past clients to inquire about their experience with the supplier.

Flexibility

Prioritize suppliers who can accommodate design changes within 24 – 48 hours of request. They should have a change order management system in place, clearly defining the impact on cost and delivery time. Ensure they can handle iterative design processes, which are common in high voltage PCB development due to strict safety and performance requirements.

Certifications

Ensure suppliers hold relevant certifications, such as ISO 13485 for medical – grade high voltage PCBs (if applicable) or UL 796 for printed wiring boards. These certifications should be up – to – date and available for verification. Additionally, look for industry – specific certifications, like those from the Institute of Electrical and Electronics Engineers (IEEE) for high voltage engineering standards compliance.

Supply Chain Management

Suppliers should have a diversified network of component suppliers, especially for high voltage – specific components like high voltage capacitors and resistors. They should be able to provide a bill of materials (BOM) with alternative part numbers in case of shortages. Request information on their inventory management system to ensure they can maintain a sufficient stock of key materials to meet production schedules.

How to Verify Your High Voltage PCB Design?

Electrical Testing: Conduct comprehensive electrical tests, including high voltage testing, continuity testing, and insulation resistance testing. These tests can identify any electrical faults or weaknesses in the design.
Thermal Testing: Use thermal imaging and other thermal testing methods to measure the temperature distribution on the PCB. This helps in detecting any hotspots and ensuring proper thermal management.
EMC Testing: Perform electromagnetic compatibility testing to ensure the PCB does not emit excessive electromagnetic radiation and is not susceptible to external interference.
Mechanical Testing: Check the mechanical integrity of the PCB, including the strength of the board, the durability of the components, and the reliability of the connections.
Functional Testing: Test the functionality of the high voltage PCB in a real – world or simulated environment to ensure it meets the required performance specifications.
Simulation Verification: Compare the simulation results with the actual test results to verify the accuracy of the design models. This can help in improving future designs.
Documentation Review: Review all the design documentation to ensure it is complete, accurate, and in compliance with the relevant standards and requirements.
Component Verification: Verify the specifications and performance of all the components used on the PCB. This includes checking for proper component selection, correct installation, and compliance with the design requirements.
Design Rule Check (DRC): Run a DRC on the PCB design to ensure it adheres to the established design rules, such as clearance, trace width, and via size requirements.
User Acceptance Testing: If possible, involve end – users in the testing process to get their feedback on the usability and performance of the high voltage PCB.

Do You Have Case Studies of High Voltage PCB Designs for Industrial Applications?

Case Study: High-Power Motor Control PCB for Industrial Robotics

Industry: Industrial Automation

Challenge:
A leading robotics manufacturer required a robust PCB to control two high-torque DC motors (15A each, 30A total) for a precision CNC machine. Key challenges included:

Withstanding voltage spikes up to 600V during motor start/stop cycles.
Maintaining thermal stability in a 24/7 operation environment.
Ensuring electromagnetic compatibility (EMC) to avoid interference with nearby sensors.

Solution:

Material Selection:

Used 2oz copper PCB with FR4 substrate (dielectric strength >300V/mil) for reliable insulation.
Applied ceramic-filled solder mask to enhance arc resistance and thermal conductivity.

Thermal Management:

Integrated 74651195R 85A screw terminals for power input and 30A snap-in connectors for motor outputs to minimize contact resistance.
Added 1000μF electrolytic capacitors to suppress voltage transients and stabilize the power rail.
Incorporated thermal vias and a 2mm copper ground plane to dissipate heat efficiently.

Safety & Compliance:

Implemented dual fuses (30A input, 15A output) and an NTC thermistor for real-time thermal shutdown.
Maintained 8mm creepage distance and 6mm air gap between high-voltage (HV) and low-voltage sections, exceeding IPC-2221B standards.

EMC Mitigation:

Designed a pi-filter network (10μH inductor + 100nF/1kV capacitor) to attenuate motor noise.
Routed HV traces on inner layers to reduce radiated emissions.

Result:

Achieved 98% efficiency with zero arc-over incidents during 1000-hour stress testing.
Thermal imaging showed a 25°C temperature reduction compared to conventional layouts.
Passed IEC 61000-4-4 ESD and EN 55032 EMC certifications on the first attempt.

Conclusion

In conclusion, high voltage PCB design demands specialized technical know-how, practical experience, and meticulous attention to detail. Mastery of design rules, guidelines, and key considerations is the foundation for crafting reliable, efficient high voltage PCBs. From troubleshooting common issues, selecting the right suppliers, to rigorous design verification—each step is non-negotiable. Our case studies showcase real-world applications across diverse industries. Ready to bring your high voltage PCB project to life? Contact sales@bestpcbs.com for a quote. Let our expertise deliver the high-quality design solutions you need.