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What Are the Advantages of Using Bus Bar PCB?
Friday, June 14th, 2024

In the design of electronic devices and systems, power distribution and heat dissipation management are key factors. Bus bar PCB, as an efficient solution, is particularly outstanding in these aspects. In this article, we would like to introduce the advantages of Bus bar PCB and its applications in different industries.

What Is A Bus Bar PCB?

At the beginning, we should know what a bus bar PCB is. The Bus bar PCB is a special and newest design that integrates the FR4 material and metal alloy into a whole product, which allows the current transfer path into the circuit board. Due to the current carry capacity and special shape, it also called busbar PCB, embedded bus bar PCB, extruded copper PCB, copper inlay PCB, copper extrusion PCB.

bus bar pcb

Bus bar circuit board provide a more compact and efficient means of current distribution than traditional wires and cables. This design improves the overall performance of the electronic system by reducing inductance, increasing current carrying capacity, and optimizing heat dissipation.

What Are the Advantages of Bus Bar PCB?

Bus bar PCB offers numerous benefits when be using the power supply applications, its main functions are:

1. Reduce the inductance

Bus bar PCBs reduce inductance by allowing current to flow between tightly spaced conductors. This layout reduces the loop area and thus the inductance value. This is particularly important for high-frequency and highspeed applications, as it reduces voltage spikes and noise, improving system stability and performance.

2. Enhanced current carrying capacity

Due to its large cross-sectional area and high-quality conductive materials, Bus bar PCB can efficiently carry large currents. This is particularly useful in applications that require a large amount of power distribution, such as power supplies, electric vehicles, and renewable energy systems. Bus bar PCBs support higher current density compared to conventional PCB wiring, which improves thermal management and reliability.

3. Improve thermal management

The Bus bar PCB effectively dissipates heat generated by key components. In high power applications, the buildup of heat can affect performance and life. The Bus bar PCB helps maintain optimal operating temperatures through efficient heat distribution, reducing the need for additional cooling mechanisms.

4. Save space and weight

The compact design of the Bus bar PCB reduces the overall size and weight of the electronic components. Its simple construction and elimination of multiple wire connectors contribute to space savings. This is particularly beneficial for applications where size and weight are critical, such as the aerospace and automotive industries.

5. Improved reliability and durability

Bus bar PCBS have superior mechanical strength and durability compared to traditional wiring systems. Its robust construction and secure connections reduce the risk of loose connections, failure due to vibration, and mechanical wear. This improves system reliability and service life for harsh environments and demanding applications.

6. Simplify assembly and maintenance

Using a Bus bar PCB simplifies the assembly process because it reduces the number of individual wires and connectors. This not only speeds up installation, but also reduces assembly errors. In addition, the Bus bar PCB provides a more orderly and accessible layout for easy troubleshooting and repair.

embeded bus bar pcb

7. Cost effective

Although there may be a high initial cost, Bus bar PCBs can provide cost savings in the long term. Its advantages in reduced inductance, improved thermal management and enhanced reliability reduce operating and maintenance costs. In addition, Bus bar PCB reduces the need for addons, such as heat sinks or complex wiring bundles, thereby increasing overall cost effectiveness.

What Applications of Bus Bar PCB?

Due the high current carry capacity of the bus bar PCB, makes it very suitable for power supply or power management devices. Bus bar PCB can perform well in such fields. Here are some common application examples that bus bar PCB can be used for. If you are seeking for a PCB to integrate into your power supply project, then bus bar PCB is the go-to-choice.

1. Power Electronics

In power converters, inverters and high-current power supplies, Bus bar PCBS are widely used because of their ability to efficiently handle high currents and excellent thermal performance.

2. The Automobile industry

Another popular field that bus bar PCB used in is automotives, especially in electric vehicles (EVs) and hybrid electric vehicles (HEVs). In the electric cars, it can be used for battery connectivity and power distribution, contributing to weight reduction and performance improvements.

3. Renewable energy

Bus bar PCB is an environment friendly material, it is often used in solar systems, wind turbines and energy storage solutions to manage high currents and enhance reliability.

4. Industrial equipment

In industrial machinery and equipment, Busbar PCB provides powerful and efficient power distribution for motors, drives and control systems.

aluminum bus bar pcb

5. Aerospace

Bus bar PCBS are used in aerospace applications, such as avionics and power distribution systems, where size, weight and reliability are key factors.

Final Words

All in all, bus bar PCB offers significant advantages in handling high currents, improving thermal management, and providing reliable power distribution across various applications. By integrating bus bar PCBs, industries can achieve better power management, reduced system size and weight, and improved overall reliability.

Best Technology is a one-stop PCB solution provider in Asia, we offer various kinds of PCBs not only include bus bar PCB, but also Extra thin PCB, RF PCB, HDI PCB, Heavy copper PCB, Ceramic PCB, Metal Core PCB, Flex PCB and rigid flex PCB, PCBA and so more. We have more than 17 years-experience in PCB design and manufacturing, and served more than 1200 customers. Choosing Best Technology as your supplier ensures you get high quality PCBs, helping to improve the performance and competitiveness of your products. Contact us right now to customize your own PCB!

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Bus Bar PCB: What are the Considerations During Designing?
Saturday, June 8th, 2024

In the electronics industry especially for new-energy vehicles, a Bus Bar PCB plays an important role to achieve specific function. It transmits large amounts of current through metal strips or conductive paths, making it ideal for high-power applications. The design of busbar PCBs is a key technical area for designers or engineers who engaged in power distribution or who require efficient current management. In this article, we would like to share some information about the considerations during a bus bar circuit board designing, hope this may help you to design a desired PCB successfully.

What is a Bus Bar PCB?

Bus bar PCB is one of a new type of heavy copper PCB and it was made by FR4 fiber glass material and laminated with metal alloys.  It transmits electrical energy from one point to multiple output points through integrated conductive paths, which are typically made of copper or aluminum. Busbar PCBs are designed to reduce resistance and inductance, thereby maximizing current transfer efficiency and minimizing energy loss.

bus bar pcb design

Generally, if it is used in a charging pile product, there are generally at least 2 busbar circuit boards, one is the main control board (a larger one), and the other is a smaller board, both of two need to use the bus bar process.

Bus bar PCB is widely used in power distribution systems, electric vehicles, industrial equipment and other occasions requiring high current. They are designed to simplify system wiring, reduce electromagnetic interference (EMI), and improve overall reliability and performance of the product.

Why is High Current Bus Bar PCB Important?

Bus bar PCB has irreplaceable advantages in current transmission and power distribution. They mainly feature three functions when used in electronics. First of all, they are able to efficiently handle large currents without generating excessive heat. This is what standard FR4 PCB cannot achieved. Secondly, bus bar PCB has ability to significantly reduce the complexity of the circuit layout design. By integrating the current transfer path, they can reduce the number and length of circuits required by the system, thereby simplifying system design and reducing potential failures.

In addition, bus bar PCB helps reduce electromagnetic interference. Due to the design optimization of the conductive path, the noise generated during current transmission can be effectively suppressed. This characteristic makes it perform well in high-noise environments, ensuring the stability and reliability of electronic devices.

What Should We Consider When Designing A Bus Bar PCB?

Due to it is a new innovation in the industry, it is a not a simple thing to design a bus bar circuit board successfully. It’s a complex task that requires consideration of several technical factors to ensure its effectiveness and reliability. The following are the main aspects to focus on when designing a bus bar PCB.

  • Copper Thickness

The first important thing is what’s the copper thickness of busbar you want to. You must know, thicker copper allows for higher current carrying capacity, but not thicker thickness is better, it should be calculated according to the voltage and current it will used in.

  • Current capacity and temperature management

The bus bar PCB should be designed to carry the maximum expected current while keeping the temperature within a safe range. This is usually achieved by selecting the appropriate conductor material and optimizing the cross-sectional area of the conductor. For example, for 100A current requirements, a typical design would use copper strips with a thickness of 5mm to ensure that the temperature rise does not exceed 20C.

bus bar pcb design
  • Resistance and inductance

Low resistance and low inductance are key to bus bar PCB design. The shape, thickness and layout of conductors should reduce resistance and inductance as much as possible to improve the efficiency of current transmission. For example, the use of trapezoidal or flat conductors can effectively reduce inductance, thereby improving current transmission performance.

  • Electromagnetic compatibility (EMC)

Bus bar PCB design also needs to consider electromagnetic compatibility issues to ensure that it does not produce too much electromagnetic interference (EMI), while being able to resist external electromagnetic interference. By optimizing the conductor layout and using shielding materials, the electromagnetic compatibility of the bus PCB can be significantly improved.

  • Thermal management

Because bus bar PCB aims to transmit high current, thermal management is an important part of the design. The thermal design should ensure that the PCB can effectively dissipate heat and prevent overheating damage. For high power applications, radiators or active cooling are often used to ensure temperature control within design specifications.

bus bar pcb design

Best Technology Manufacturing Capability of Bus Bar PCBs

As the one of leading PCB manufacturers in China, Best Technology has exceptional capabilities in the production of busbar PCBs. Our manufacturing capabilities include high-precision metal processing technology to produce busbar PCBs with complex geometry and tight tolerances. In addition, we also have the production capacity of multi-layer bus bar PCB to meet the needs of different applications.

Best Technology is committed to providing customers with high-quality, high-performance busbar PCBs to support their power management and distribution systems. Below is a basic parameter of our bus bar PCB manufacturing capability. For more details, welcome to e-mail us at sales@bestpcbs.com.

Best technology capability of bus bar pcb
(Best technology capability of bus bar pcb)

Nowadays, bus bar PCBs are widely used in power distribution systems, electric vehicles, industrial equipment and other occasions requiring high current. According to statistics, the global busbar market is expected to grow at a compound annual growth rate (CAGR) of 6.5% between 2023 and 2028, demonstrating the growing importance of this technology in multiple industries.

With the rapid development of the eras, the most important thing for designers or buyers is to find a reliable bus bar PCB manufacturer to meet the high demands of the market. As the expert of the bus bar PCB fabricating, Best Technology has the mature technology and advanced equipment to produce high quality bus bar PCBs. Contact us right now to get your own bus bar PCB solutions!

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Why is FR4 Material the Most Commonly Used PCB Material?
Wednesday, June 5th, 2024

FR4 material is a highly popular and widely used substrate in the PCB industry due to its exceptional mechanical strength, electrical insulation, and flame retardant properties. It has become the standard for PCB fabrication.

What is FR4 Material and Why is it Used in PCBs?

FR4 is a type of fiberglass-reinforced epoxy laminate. The term “FR4” comes from its flame-retardant properties, meeting the UL94V-0 standard. It is made from woven fiberglass cloth and epoxy resin, which together provide great strength and durability.

Electrical engineers and designers prefer FR4 because of its many benefits, such as:

  • Low cost
  • High dielectric strength
  • Excellent strength-to-weight ratio
  • Moisture resistance
  • Temperature endurance
  • Good electric loss characteristics
  • Flame retardance and self-extinguishing capabilities
  • Mechanical robustness
  • Insulating properties

FR4 is also suitable for marine PCBs because it absorbs very little water. In a standard FR4 PCB, a layer of FR4 is placed between two thin layers of laminated copper.

FR4 material pcb

What are the Key Performances of FR4 Material?

FR4 material, also recognized as flame retardant 4, is a composite of glass fabric and epoxy resin, predominantly utilized as a foundational material for printed circuit boards. Familiarity with the specifications of FR4 is crucial for selecting the appropriate substrate for PCB manufacturing. Key specifications include:

1. The thickness of FR4 sheet is usually 0.2 mm to 3.2 mm, and other special thickness also available.

2. The specific gravity of FR4 material is about 1.85g/cm3, which means that it is heavier than water.

3. Coefficient of thermal expansion of FR4 is about 1.0×10^-5cm/cm/℃, which means that its length or width will expand slightly when the temperature changes.

4. The thermal decomposition temperature of FR4 materials is usually between 280C and 320C, which makes it able to withstand high temperature applications.

5. FR4 material has a dielectric constant around 4.0-4.8, which makes it an ideal material for circuit board manufacturing.

6. FR4 has good arc resistance, which means that in the case of high voltage, it can effectively prevent arc discharge.

7. FR4 material good hydrolysis resistance and can maintain good performance even in a humid environment.

RF FR4 PCB

What are the Types of PCB Materials in the Industry?

PCB materials can be broadly categorized based on their composition and intended application. Nowadays, the commonly used are including FR4, polyimide (PI), Metal material (copper or aluminum), ceramic substrate like Al2O3, AlN, Si3N4, and so on. Different materials have its unique functions and well-suited in specific environment. Here we introduce their properties and suited applications simply.

FR4 (Fiberglass Epoxy Laminate)

At present, almost of PCB you seen in the market or electronics used the FR4 material. It widely used because of its superb equilibrium of mechanical strength, electrical insulation, and cost-efficiency. Actually, according to the different reinforcement materials, the circuit board is mainly classified into the following types:

1) FR-4

2) FR-1, FR-2, etc.

3) CEM series: Composite substrate

FR-4 used frequently because of its high fire resistance rating.

High Tg FR4

Though normal FR4 material has good electrical insulation, it is not an ideal option for high frequency circuit board. And then, high Tg FR4 stands out by using an advanced technology. “Tg” refers to glass transition temperature, the juncture at which the material transitions from a rigid, glassy state to a pliable, rubbery state. High Tg FR4 boasts a Tg of 170°C or higher.

Polyimide (PI)

Polyimide materials are renowned for their excellent flexibility, superior thermal stability and chemical resistance. It is always used as raw material of flex circuits, rigid flex circuit boards or membrane switches. Due to the good chemistry properties, they can endure temperatures up to 260°C and are highly flexible, making them ideal for those small and limited PCB designs.

polyimide pcb

Metal base material

Metal materials always used in metal core PCBs (MCPCB), usually used aluminum core or copper core. The metal base has great thermal conductivity to enhance the thermal management of the device, buy using metal core, the device can dissipate heat away from the critical component such as LED chips, ICs, BGAs, to remain the reliability and performance of the PCB.

metal core pcb

Ceramic substrate

Ceramic PCB substrate offers excellent thermal conductivity and stability than that metal core PCBs, making them suitable for high-power and high-frequency applications. But due to the high cost and complex manufacturing, the ceramic PCB is much expensive than metal core PCB, therefore, they are always be used in high-end applications, such as the military, defense, aerospace and some special fields where requires excellent thermal management.

ceramic pcb

Understanding these materials enable to help engineers and designers in selecting the most appropriate substrate for their projects, ensuring optimal performance and cost-efficiency. Best Technology provides a comprehensive array of PCB materials, guaranteeing high-quality solutions for all your electronic needs.

What are the Applications of FR4 PCB Material in Various Industries?

FR4 material is versatile and finds applications in numerous industries, including:

  • Consumer Electronics like smartphones, laptops, and other personal electronic devices.
  • Applied in vehicle electronics for infotainment systems, engine control units, and more.
  • Industrial Equipment such as control systems, power supplies, and industrial automation.
  • Essential for telecommunications, network devices, routers, and communication infrastructure.
  • Medical instrumentation and diagnostic equipment.
  • Aerospace and defense in avionics, radar systems, and defense electronics.

This is all of this sharing, thanks for your reading. Welcome to contact us if you have other questions about FR4 or other raw materials of PCB. Best Technology engaging in the PCB manufacturing about 18 years, we are one of the leading PCB manufacturers in China. And we have such confidence to provide with you the best PCB and PCBA fast solution for your projects.

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What are HDI PCBs and Their Basic Parameters?
Wednesday, June 5th, 2024

High-Density Interconnect (HDI) PCBs are revolutionizing the electronics industry with their advanced capabilities and compact designs. As technology continues to evolve, the demand for smaller, faster, and more efficient electronic devices has led to the widespread adoption of HDI PCBs.

What is Definition of HDI PCB?

HDI board refers to High Density Interconnect, that is, high density interconnect board, which is a relatively new technology developed by the PCB industry at the end of the 20th century.

The drilling of the traditional PCB board is affected by the drilling tool, and when the drilling aperture reaches 0.15mm, the cost is already very high, and it is difficult to improve again. The drilling of HDI board no longer relies on traditional mechanical drilling, but uses laser drilling technology. (This is why it is sometimes called a laser plate.) The hole diameter of the HDI board is generally 3-5mil (0.076-0.127mm), the line width is generally 3-4mil(0.076-0.10mm), the size of the pad can be greatly reduced, so more line distribution can be obtained within the unit area, and the high-density interconnection comes from this.

Smaller device spacing, more I/O pins and embedded passive devices Larger ASiCs and FPGAs with increasingly shorter rise times and higher frequencies all require smaller PCB feature sizes, which is driving a strong demand for HDI/ micro through-holes. The typical high density interconnector designs are including:

  • 1+N+1
  • 2+N+2
  • 3+N+3
  • 4+N+4
HDI PCB

What are the benefits of HDI PCB?

HDI is a compact circuit board designed for small volume users. Compared with ordinary FR4 PCB, the most significant feature of HDI is the high wiring density, and the difference between the two is mainly reflected in the following three aspects.

1. HDI is smaller and lighter

HDI board is a traditional dual panel as the core board, through continuous stacking layer by layer. This kind of circuit board made by continuous layering is also called Build-up Multilayer (BUM). Compared with traditional circuit boards, HDI circuit boards have the advantages of “light, thin, short and small”.

The electrical interconnection between the HDI board is realized through the conductive through hole, buried hole and blind hole connection, its structure is different from the common multi-layer circuit board, and a large number of micro-buried blind holes are used in HDI board. HDI uses direct laser drilling, while standard PCBS usually use mechanical drilling, so the number of layers and aspect ratio tend to be reduced.

The high density of HDI board is mainly reflected in the hole, line, pad density, and layer thickness.

● Micro-via hole

The HDI board contains the design of micro-pilot holes such as blind holes, which is mainly reflected in the micro-hole formation technology with a diameter less than 150um, and the high requirements of cost, production efficiency and hole position precision control. In the traditional multilayer circuit board, there are only through holes and no tiny buried blind holes.

● Fine line width and line distance

Its main performance in the wire defects and wire surface roughness requirements are more and more stringent. Generally, the line width and line distance do not exceed 76.2um.

● High pad density

The density of welded contacts is greater than 50 per square centimeter.

● Thinning of medium thickness

It is mainly manifested in the trend of the thickness of the interlayer medium to 80um and below, and the thickness uniformity requirements are becoming more and more stringent, especially for high-density plates and packaging substrates with characteristic impedance control.

2. Better electrical performance

    HDI not only enables end-product designs to be miniaturized, but also to meet higher standards of electronic performance and efficiency at the same time.

    The increased interconnect density of HDI allows for increased signal strength and improved reliability. In addition, the HDI board has better improvement for RF interference, electromagnetic wave interference, electrostatic discharge, heat conduction and so on. HDI also uses full digital signal process control (DSP) technology and a number of patented technologies, with a full range of load adaptability and strong short-term overload capability.

    3. The HDI board has very high requirements for buried holes

    It can be seen from the above that whether it is the volume of the board, or the electrical performance, HDI is better than ordinary PCB. Where the coin has two sides, the other side of HDI is as a high-end PCB manufacturing, its manufacturing threshold and process difficulty are much higher than ordinary PCB, and there are more problems to pay attention to when producing – especially the buried hole jack.

    What are the basic parameters of HDI PCB?

    HDI PCB has greater different with normal FR4 PCB, from the stack up, material selection, manufacturing and cost. So, it is vital to understanding the basic parameters of a high-density interconnect board before start your designing trip. The standard parameters of HDI board mainly include the following aspects:

    1. Numbers of layers

    Generally, the number of layers of HDI board is 4-20 layers, and the high-end HDI board can reach to 40-50 layers.

    • Line width/spacing

    Due to the HDI PCB are always used in high-end applications, their line width and spacing are usually very strict, and the common requirement is that the line width/spacing is 4/4mil (0.1mm), or even smaller.

    • Blind hole, buried hole, bus

    These are one of the characteristics of the HDI board, blind hole and buried hole can reduce the area of the circuit board, make your design more density, and the bus enable to improve the signal transmission rate of the PCB.

    • Board thickness

    The board thickness of HDI board is usually range from 0.8 to 3.2mm, of which 1.6mm is the most common thickness.

    • Pad

    The pad on the HDI board is generally very small, and the common pad size is 0.2mm to 0.5mm. Different factory has different capabilities, it is best to ask your supplier or manufacturer to get a manufacturing capability document.

    • Impedance control

    For high-speed signal transmission circuits, the impedance control of the HDI board is very important, and the requirements are very strict. It is needed to tell your vendor if your HDI board will be used in high-speed devices.

    • Material

    The main materials of HDI board are FR4, BT, PI, PET, etc. Different materials can meet different requirements.

    This is the end of this sharing, contact us today to learn more about our HDI PCB solutions and how we can help you achieve your technological goals. In our next chapter, we will introduce the manufacturing process and methods of HDI boards, let me know if you are interested in it.

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    What is the Flexible Aluminum PCB?
    Wednesday, May 29th, 2024

    Flexible aluminum PCB is a new development in the recent years, it enables people decrease the size of certain products in some area. Different from the rigid flex PCB, flexible aluminum PCB combines the flex circuit and aluminum core circuit board (or can be copper core PCB), so it has the rigidity and good thermal management of traditional Aluminum PCBs with the flexibility of polyimide, these hybrid boards offer a host of advantages.

    To increase the thermal conductivity in high power applications, and meet the flexibility requirements, flexible aluminum PCB is a good option. This article explores the key benefits of flexible Aluminum PCBs, highlighting why they are becoming increasingly popular in various applications.

    flexible aluminum pcb

    What is Flexible Aluminum PCB?

    Flexible aluminum PCBs are a type of printed circuit board that uses an aluminum base material and is designed to be flexible. Unlike standard aluminum PCBs, these boards can bend and conform to different shapes, making them ideal for applications where space and flexibility are crucial. And Have you ever heard about our another aluminum board that we called bendable aluminum PCB? This is a special metal core circuit board that uses special material makes the circuit board bendable while won’t damage the board. May you think both of two are the same product? No, they are different in the constructure and raw materials, and the manufacturing processes are different as well.

    Bendable aluminum PCB uses aluminum alloy as the raw material, considering it must meet the bendable requirement as well as the good thermal management during using, it must be specially designed aluminum alloy composite material. And the aluminum base thickness also is a key consideration, 0.2mm to 1.0mm always are the common bending metal substrate thickness. Meanwhile, the bending radius of bendable aluminum PCB also should be calculated before manufacturing, making it follow the bending design standard to smooth the manufacturing. It is the same as flexible aluminum PCB.

    bendable aluminum pcb

    What Are the Constructure of Flexible Aluminum PCB?

    Flexible aluminum PCBs combine the benefits of aluminum’s excellent thermal management with the flexibility required for modern electronic designs. These PCBs are constructed using a combination of materials and layers that provide flexibility, durability, and efficient heat dissipation. And compared with original aluminum PCB, it adds the flexible insulation layer and the content of adhesive glue is different.

    • Aluminum base layer

    The aluminum base layer serves as the foundation of the flexible aluminum PCB. It provides structural support and excellent thermal conductivity. Typically, high-quality aluminum is used for this layer due to its superior thermal properties and mechanical strength.

    • Dielectric layer

    It acts an insulator between the aluminum base and copper foil, it can allow the heat pass through while electrically insulating the conductive pathways.

    • Copper foil

    The copper foil forms the conductive pathways that carry electrical signals and power across the PCB. It is essential for the functioning of the electronic components connected to the PCB.

    • Flexible layer

    Common materials for this layer include polyimide (PI) or polyester (PET), both known for their flexibility, thermal stability, and insulating properties. It contributes to the overall flexibility of the PCB, allowing it to bend and conform to various shapes.

    • Protective overlayer

    This layer is applied over the copper circuits to protect them from environmental factors such as moisture, dust, and physical damage. It also provides mechanical support to the flexible areas. Normally called solder mask layer.

    The Difference Between Flexible Aluminum PCB and Flex Circuits

    While both aluminum flex PCBs and flexible printed circuits (FPCs) offer flexibility, they differ significantly in their materials and manufacturing costs:

    ItemFlexible Aluminum PCBFlex Circuit (FPC)
    Base MaterialAluminum corePolyimide or PET
    Conductive MaterialCopper foil and aluminum for the conductive tracesVarious materials like polyimide, PET or the copper foil
    FlexibilityLimited in specific areaFlexible everywhere
    Thermal ConductivityHigh thermal conductivityDepends on the material used
    Manufacturing ProcessComplexRelatively simple
    Specific AdvantageFast heat dissipationGeneral part in electronics
    CostHighCost-effective
    (Comparison between flexible aluminum PCB and flex circuit)

    What Are the Benefits of Using Flexible Aluminum PCB?

    Flexible aluminum PCB has numerous advantages that make it highly preferrable for specific applications, including:

    • Excellent thermal management

    Due to the applied of aluminum base, efficient heat dissipation prevents overheating and extends the lifespan of electronic components.

    • Lightweight and flexible design

    Due to the flexible and lightweight features in the flex aluminum PCB, it can be bent and shaped the PCB reduces the need for additional connectors and saves space in compact designs.

    • Improve reliability

    Aluminum based PCB has good durable, ensures the long-lasting performance of the whole product, even in harsh conditions.

    • High density integrated

    The flexible aluminum PCB allows for the higher density circuit layouts than normal aluminum PCB.

    • Effective electromagnetic shielding

    Aluminum material provides electromagnetic shielding in a certain degree, which helps to reduce the impact of electromagnetic interference on the circuit.

    flexible aluminum pcb

    How to Choose A Reliable Flexible Aluminum PCB Manufacturer?

    Selecting the right manufacturer for flexible aluminum PCBs is crucial for ensuring quality and reliability. Make sure your supplier has extensive experience in this field and obtained relevant certifications like UL, CE, ISO9001 and so on.

    Best Technology is a China-based PCB and PCBA manufacturer, who has over 17-years-experience circuit board manufacturing. At Best Technology, we specialize in providing high-quality flexible aluminum PCBs tailored to meet your specific needs. And we were certificated by ISO9001 quality control system, ISO13485 for medical device and IATF16949 for automotive system. Our expertise and commitment to excellence ensure that you receive the best solutions for your electronic applications. Choose Best Technology for your PCB requirements and experience the benefits of advanced PCB technology.

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    What is the Rogers Printed Circuit Boards?
    Monday, May 13th, 2024

    Rogers Printed Circuit Board (short for Rogers PCB) is a printed circuit board (PCB) manufactured using a special high-frequency material produced by Rogers Corporation. These boards are designed to meet the demanding performance requirements of high-frequency electronic devices, especially in wireless communications, microwave technology, high-speed digital signal processing, radio frequency (RF) products, and applications requiring extremely high stability and low signal loss.

    Rogers pcb made by best technology

    What are the Main Features of Rogers Printed Circuit Board?

    Rogers boards are made of a proprietary amide resin material, which gives them excellent dielectric properties, thermal stability and mechanical strength. Even in extreme working environments such as high temperature and humidity, high frequency and high speed, Rogers PCB board can maintain stable operation, showing its strong adaptability and reliability. Whether it is to improve the performance of electronic equipment, or to ensure the stability of the system, Rogers PCB board plays a vital role. Below are some main features and benefits of Rogers PCB.

    • Special substrates

    Unlike traditional PCB materials based on glass fiber reinforced epoxy resins such as FR-4, Rogers PCBs are ceramic filled or based on high-performance substrates such as liquid crystal polymers (LCP), for example, RO4350B, RT/duroid series, TMM series and TC series. These substrates provide excellent electrical properties, such as low dielectric constant (εr) and low dielectric loss factor (Df), ensuring low signal loss and high-speed during transmission.

    • High frequency performance

    Rogers PCB is particularly suitable for high frequency applications, because its material characteristics make the circuit board can maintain extremely low signal attenuation and stable electrical performance at operating frequencies up to tens or even hundreds of GHz. This makes them excellent in radar systems, satellite communications, 5G/6G network equipment, radio frequency identification (RFID) systems, high-speed data transmission interfaces (such as USB, PCIe) and other applications.

    • Temperature stability

    Rogers material has excellent thermal stability and low coefficient of thermal expansion (CTE), which matches the thermal expansion rate of copper foil, helping to reduce the stress and deformation caused by temperature changes, ensuring the reliability of the circuit when working in a wide temperature range.

    • Mechanical strength and heat resistance

    Due to the use of high-performance composite materials, Rogers PCB usually has high mechanical strength and good high temperature resistance, and can adapt to harsh environmental conditions and heat dissipation requirements.

    • Surface treatment

    Rogers PCB can carry out a variety of surface treatments, such as gold plating, silver plating, organic welding film (OSP), etc., to meet the specific requirements of different applications for weldability, oxidation resistance, contact resistance, etc.

    • Multi-layer structure and fine traces

    Rogers PCB can be made into single-layer to multi-layer structure, support high density interconnect (HDI) design, with fine lines (such as line width/line distance up to 0.3mm or smaller) and small aperture (such as 0.3mm), suitable for complex and precise high-frequency circuit design.

    • Low moisture absorption

    Rogers material moisture absorption rate is very low, even in high humidity environment can maintain stable electrical performance, reduce the impact of moisture on dielectric properties, to ensure long-term reliability. In summary, Rogers printed circuit board is a high-end, professional-grade circuit board product, with its excellent high frequency characteristics, stable electrical performance, excellent temperature stability, and wide applicability, becoming the ideal choice to meet the demanding requirements of modern high performance electronic equipment and communication systems.

    Why Use Rogers Printed Circuit Boards?

    High frequency PCBs often need high performance with low signal losses, low electrical noise, or high board temperatures. To meet this need Rogers Corp. PCB materials are often used as they are cost effective vs. many of the alternatives. Here are some typical Applications for Rogers PCB:

    All kinds of the Microwave equipment.

    5G Cellular Base Station Antennas and Power Amplifiers

    Automotive Radar and Sensors

    RF Identification (RFID) Tags

    Direct Broadcast Satellites for low noise block downconverter

    Medical equipment such as monitoring instrument, cardiac pacemaker, MRI, etc.

    Military and aerospace

    Rogers pcb made by best technology

    Rogers series is often used in RF PCBs with frequencies 6+ GHz and in high heat applications that need ceramic laminates and low signal losses. It may also be used to minimize electrical noise to meet stringent performance requirements.

    In our next blog from Best Technology, we are going to share more information about different material from Rogers PCB. pls follow us and if you want to know more about the Rogers PCB, warmly welcomed to visited www.bestpcbs.com or email us, it would be our great pleasure to answer all the questions for Rogers PCB.

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    What Uses Would Ultra-Thin Printed Circuit Boards Find?
    Tuesday, April 23rd, 2024

    This category of ultrathin printed circuit boards is characterized by a thickness lesser than standard FR4 PCBs and generally finer than 0.60mm. But sometimes, due to space or margin limitation, or even design purposes, people need much thinner thickness such as 0.25 mm, 0.20 mm, or even 0.15 mm, so that it can be used by the PCB, such as SIM Card, Sensor Card, and so on. Due to thin thickness, extra thin PCB or very thin PCB name has been coined.

    ultrathin pcb

    What are the Applications of Ultra-thin PCB?

    Ultra-thin printed circuit boards (PCBs) are quite specialized items, helpful to find applications in several industries due to their flexibility, reduced weight, and space requirements. Given below are a few areas wherein ultra-thin PCBs would add more value:

    1.   Wearable Technology

    With wearables dictating minimalist designs, thin PCBs offer just the right solution. Their thinness ensures a perfect fit in wristbands, smart clothing, and medical patches for an improved user experience in comfort and battery life.

    2.   Mobile Devices

    The same can be said about PCBs as the relentless race continues for ever-thinner smartphones and tablets. Being thinner will continue enabling engineers to shove more processing power into a tight space.

    3. Aerospace and Defense

    In the world of satellites and drones, weight is critical. Besides being rugged, thin PCBs are lightweight; they allow intensive avionics systems to function faultlessly without adding their own unwarranted heft.

    ultrathin pcb

    4.   Flexible and Foldable

    Innovators can easily create new product designs using flexible PCBs that bend and flex. From foldable phones to curved displays, the product will survive repeated cycles of bending and yet have low impedance.

    5.   Medical Devices

    Miniature implantable medical devices require PCBs that are both small and biocompatible. Thin PCBs fulfill this need because they assist medical devices in being used in minimally invasive procedures and, besides, by way of example, give patient comfort since such patients can wear these devices for long periods.

    Which Kind of Surface Finishing Can be Used on Ultra-thin PCB?

    Common surface treatments used in extra thin PCB often include OSP (Organic Solderability Preservative), ENIG (Electroless Nickel Immersion Gold), or hard gold plating for the very best durability, conductivity, and environmental resistance. Now, thin PCB technology becomes a great enabler for industries that have an unparalleled level of miniaturization and functional density.

    As we continue to shrink the world of electronics, the role of thin PCBs is set to expand exponentially.

    Stay tuned for the latest thin PCB manufacturing developments that will have real potential to completely change how thin PCBs are conceptualized and used in modern electronics design. If you would like to harness the power of thin PCBs for your next project, feel free to engage a trusted PCB expert to unlock unparalleled benefits in size, weight, and performance. Learn more about the capabilities of thin PCB fabrication and the applications they are used in industry. Ensure that the Anchor Text is keyword-rich: Discover More About Thin PCB Fabrication Capabilities and Industry Applications.

    ultrathin pcb

    We hope this comprehensive article has been able to clarify doubts about Ultrathin PCBs. If you require any other service or have any question, do not hesitate to contact us. Our dedicated staff with 18 years of experience in the electronics manufacturing field is ready to present unbeatable service to you and make your dream for Ultrathin PCB come true. Talk to us for all your custom solutions and the best customer service. We are committed to making sure you get satisfaction and are bound to offer you nothing short of the best for your Ultrathin PCBs. Get in touch with us today and let us take your project to the next level.

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    Do You Know What Is PCB Stiffener Busbar?
    Wednesday, March 27th, 2024

    Busbar PCB is an electronic component, also known as a socket board or mother board, which is an important part of an electronic device and is used to connect and transmit current and signals, so it plays a crucial role in the design of electronic devices. Busbar PCB is like a PCB coated with an “ear”, which we also call it as stiffener busbar. Want to know more about it? Welcome to reading on!

    (Busbar_pcb)

    What is PCB Stiffener Busbar?

    A busbar circuit board is a key component used in electrical systems. It usually consists of a main conductive busbar (usually copper or aluminum) that is covered with an insulating material such as prepreg or resin. Busbar boards are used to transmit high currents in power systems, such as in industrial equipment, power distribution systems, and control panels.

    These boards typically have multiple slots for inserting electrical connectors or electrical devices. The design of the bus board can be customized according to the specific application requirements to adapt to different current and voltage requirements. They are widely used in the industrial and commercial sectors because they provide reliable power transmission and connectivity solutions.

    (Busbar_aluminum_pcb)

    What Are Benefits of Using a Busbar PCB?

    Busbar stiffener pcb serves as a crucial element of conducting electricity, especially when simplifying the power distribution process, saving costs and requiring greater flexibility. They come in a variety of sizes and different coatings, such as aluminum and copper. The material type, dimension, size and shape of the busbar determine the current capacity it can carry. Compared with a coil harness, though it is expensive in manufacturing, but has longer life and does not need to replace in a short time. Here we listing some benefits of busbar PCB:

    • Efficient Power Distribution

    With the fast development of new energy cars and vehicles, the electronic parts in the cars also should updated to meet the demands of renewable energy powers. So the busbar PCB stands out because it can distribute the powers in devices efficiently. Meanwhile, it also can help to reducing the consumption of energy. Because of its integrated nature, it can easily adapt to the integration of renewable energy, which is quite intriguing to consider in this advanced era of energy.

    • High Conductivity

    The busbar stiffener on a PCB is typically crafted from either copper or aluminum. Copper, renowned for its excellent conductivity, stands out as the preferred material for busbars due to its capacity to facilitate the flow of electrons. Moreover, copper’s robust nature enables it to withstand harsh environmental conditions and high temperatures, thus bolstering its longevity and durability. But if you want PCB that can carry higher conductivity, ceramic PCB is the best choice but a little bit higher cost.

    (Busbar_copper_pcb)
    • Can be Customized

    Busbar is a highly customization product in PCB design, it offers various options for its mechanical capability. So maybe you can find it in every industry, such as educations, medical instruments, factories, communications and various electronic devices. Tight space and compact devices require substitute electrical distribution, and busbars serve the purpose right. Due to its high compact and strong mechanical and chemistry, busbar PCB can be used in extremely harsh weather. This makes them a good choice in substations or devices that need to used outdoors.

    • Space Saving

    Due to the copper materials mounted on the PCB, Busbar PCBs can replace multiple traces with a single, wider conductive strip, saving valuable space on the board. This compact design is particularly useful in applications where space is limited. In addition, busbar PCB provides multi-layer structure when your design is complex and has density traces network.

    By means our extensive PCB & PCBA manufacturing and professional engineering team, we are highly able to build and design busbar PCBs according to your specific requirements. Meanwhile, we follow the strict quality system to make sure the high-quality of products. You are welcome to contact us or send e-mail if you want to make such busbar stiffener PCB.

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    Top 1 Design and Manufacturing Considerations for Bendable Aluminum PCBs
    Thursday, March 7th, 2024

    You know, bendable aluminum PCBs have gained prominence in various electronic applications due to their unique ability to flex and conform to curved surfaces. Unlike traditional rigid PCBs that are commonly composed of materials like fiberglass , these PCBs utilize aluminum as the base material, allowing it bendable and flexibility when needed. Compared to the rigid characteristics of traditional metal core PCB, bending aluminum PCB can be adapted to specific space requirements and shape requirements. In this article, we will introduce the characteristics of bendable aluminum PCBs and explore the key considerations that engineers and manufacturers need to pay attention during the design and production process.

    What Are the Benefits of Bendable Aluminum PCBs?

    May some designers are reraly to know the bendable aluminum PCB, in their congnition, the bendable PCBs are including flex circuits, rigid flexible circuit and FFC, and aluminum PCB is classfied into one of rigid PCB. But here, Best Technology is so proud to say, we have developed bendable aluminum PCB and we can manufacture it with fast delivery and high-quality, this is what we prouded.

    The primary advantage of bendable aluminum PCBs is their flexibility. They can be bent and shaped to fit into various form factors and designs, making them suitable for applications where space is limited or where flexibility is required and traditional rigid boards are not ideal. Common applications include wearable devices, curved displays, and other electronic systems with unconventional form factors.

    Additionally, bendable aluminum PCB has the advantages of aluminum, so it has good heat dissipation and higher thermal management than traditional PCBs. This feature is crucial for maintaining the reliability and performance of electronic devices, especially those operating in high-temperature environments.

    Considerations During the Design Process

    Al Material Selection:

    Considering that it is a bendable aluminum substrate, it must be satisfied that the material selection should be bendable but at the same time have good heat dissipation of the metal base. This aluminum base material is a specially designed aluminum alloy or aluminum base composite material. Meanwhile, the thickness of the material is critical, such as the material is generally from 0.2mm to 1.6mm, of which 0.2mm to 1.0mm is the more common bending metal substrate thickness.

    Flexibility Requirements:

    Defining the flexibility requirements is a crucial step in the design process. The degree of bending, bending radius, and any other factors related to flexibility must be clearly defined based on the intended application. For instance, a wearable fitness tracker might require a specific bending profile to comfortably conform to the curvature of the wrist.

    Also note that the bending radius is different for materials of different thicknesses. In general, a smaller bending radius usually corresponds to a thinner board material, while a larger bending radius can accommodate a thicker board material.

    Circuit Layout:

    The layout of the circuit components plays a pivotal role in ensuring the longevity of bendable aluminum PCBs. Designers should strategically plan the arrangement of components to accommodate bending without subjecting critical elements, such as sensors or microcontrollers, to excessive stress. Even distribution of components contributes to a balanced bending profile.

    And the pad should not be designed at the bend of the bending, which will cause damage to the assembly components after bending, or even no way to bend. In addition, the welding pad near the bending cross should also be kept away from the bending line to avoid collision and extrusion of the components after bending.

    Bending Radius:

    Determining the minimum bending radius that the PCB can tolerate is essential for preventing structural damage or compromise in electrical performance. Specific bending radii should be defined based on the application’s needs. For example, a bendable aluminum PCB designed for a wearable device might need to withstand repeated bending with a predefined radius.

    Dielectric Layer:

    Choosing an appropriate dielectric material is crucial for maintaining insulation between different layers of the PCB. The dielectric layer should possess flexibility to withstand bending without compromising its insulating properties.

    As we know, when design the aluminum PCB, the thermal conductivity is also important. Bendable aluminum also has the thermal conductivity requirement, but when the thermal conductivity material is higher, the higher the content of ceramic powder in material. And when the content of ceramic powder is higher, the brittleness of the material is higher, and it is easier to break or break after bending. The material of 1W/m.k is more bendable than 3W/m.k。

    (Bendable_MCPCB)

    Considerations During the Manufacturing Process

    Bendable aera line:

    For the production requirements of the light plate, the V-cut mark is generally used to determine the complete line at the bend, and attention should be paid to the depth control of the v-cut, so as not to damage the line.

    Testing and Validation:

    Prototyping is a vital phase in the manufacturing process of bendable aluminum PCBs. Thorough testing and validation are necessary to ensure that the PCB meets the required electrical and mechanical specifications. Bending tests simulating the intended application conditions should be performed to assess the PCB’s durability. such as bending test, bending angle test.

    Generally speaking, after the bare board finished, it’s not bendable to the required angle. In order to avoid bad transportation or collision, some customers require not to bend and they will bend it by themselves. But if the customers don’t want to bend the board by himself, we also can help to bend it, it will require mold and it need to custom the package for shipping. The custom package can help to protect the damage in shipping.

    Collaboration with Manufacturers:

    Close collaboration with experienced PCB manufacturers is key to successful production. Manufacturers with expertise in flexible PCB fabrication can provide valuable insights into the manufacturing process. Working together ensures that the design aligns with manufacturing capabilities, optimizing the production of bendable aluminum PCBs.

    Conclusion

    In a word, the design and manufacturing of bendable aluminum PCBs involve a series of critical considerations to ensure the success and reliability of the final product. From material selection and flexibility requirements to testing, validation, and compliance with industry standards, each step plays a pivotal role in creating PCBs that meet the unique demands of modern electronic applications. By carefully addressing these considerations, designers and manufacturers can unlock the full potential of bendable aluminum PCBs in diverse and innovative electronic devices. Welcome to contact Best Technology if you want to know more.

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    How Does the Ceramic PCB Works in IGBT Modules?
    Friday, January 19th, 2024

    IGBT (Insulated Gate Bipolar Transistor) is a bipolar junction transistor (BJT) with a MOS gate, or we can say that an IGBT module is a combination of BJT and MOS module. Despite its small size, the IGBT chip can control the transmission of electrical energy. It can switch the current 100,000 times within 1 second under an ultra-high voltage of 650 million volts.

    What is the Working Principle of IGBT?

    IGBT combines the features of a transistor and a switching circuit, making it a new type of electronic component that can control current efficiency. Its structure allows it to achieve current control from turn on to off without generating excessive leakage current, as well as not affecting the operation of other circuits.

    The working principle of IGBT modules including two parts – the current control of MOS gate and BJT transistor. When the voltage of MOS gate changes, it affects the conduction of the transistor, thus controlling the flow of current. When the BJT comes into play, it controls the flow of current, so that improve the working efficiency of the IGBT.

    (Working_principle_of_IGBT)

    How Does A Ceramic PCB Protect IGBT Modules from Overheat?

    As you know, IGBT modules have been applied for many years in various industries such as automotive, industrial, aerospace, consumer electronics, and more. However, optimizing the thermal dissipation of IGBT packaging is crucial to enable the modules to operate at higher power conditions. If heat dissipation is improved, IGBT modules can be used in more advanced applications.

    You might be wondering how much heat does an IGBT module generate during running? It’s equivalent to the heat produced by 100 electric furnaces. This substantial amount of heat must be dissipated immediately from the IGBT chip, that’s why the ceramic circuit board stands out.

    (Ceramic_pcb_with_DPC_technology)

    In IGBT modules, ceramic PCBs are placed beneath the IGBT chip, or we can say the chip is assembled on the ceramic circuit board. The ceramic PCB connects and supports the chip, rapidly dissipating heat to the outer package. This method protects the chip from the adverse effects of heat.

    Why ceramic PCBs Are Suitable for IGBT thermal dissipation?

    Ceramic materials exhibit excellent thermal dissipation and electrical insulation properties. Unlike aluminum metal core PCBs, ceramic PCBs do not use insulation layers that hinder heat dissipation. In the manufacturing process of ceramic PCBs, copper foil is directly bonded to the ceramic substrate under high pressure and temperature (it depends on the different technology and different copper thickness). During PCB manufacturing, IGBT and other components are mounted on the circuit board through assembly technology.

    Ceramic materials have extremely high insulation capabilities, enduring breakdown voltages up to 20KV/mm. At present, there are three ceramic materials that can be used for IGBT modules, they are 99% or 96% Alumina (Al₂O₃), Aluminum Nitride (AlN), and Silicon Nitride (Si₃N₄).

    The thermal conductivity of alumina PCB is 15-35W/mK, aluminum nitride PCB is 170-230W/mK, and silicon nitride PCB is 80+W/mK. In contrast, aluminum core circuit boards only have a thermal conductivity of 1-12W/mK.

    Applications of Ceramic PCBs in IGBT Packaging

    Alumina PCBs are the most commonly used circuit boards in IGBT modules due to their lower cost. But if IGBT modules have higher power or precision requirements, AlN ceramic PCBs and Si3N4 PCBs are the most suitable choices. Because they have higher thermal dissipation and thermal expansion coefficients (CTE) close to semiconductors. Since different ceramic substrate has different features, the uses of ceramic PCB should depend on the specific requirements of IGBT modules.

    In addition, with the development of Silicon Carbide (SiC) and Gallium Nitride (GaN) materials, they are starting to be used for IGBT chips due to their high-frequency, high-power, and high-temperature characteristics. Maybe in the future, aluminum nitride PCBs and silicon carbide PCBs will be increasingly applied to high-power IGBT modules in high-density three-dimensional packaging.

    Common Properties of Using Ceramic Circuit Board

    • Excellent thermal conductivity and voltage resistance of ceramic substrates.
    • Copper trace layers has extremely high current-carrying capacity.
    • Strong adhesion and reliability between circuit layers and ceramic substrates.
    • Good soldering performance, suitable for wire bonding.
    (Ceramic_PCB)

    How to Solve the Overheat Issues in IGBT?

    Though the ceramic PCB is good at heat dissipation, there still some overheat occasions happened if small power or long-time operation. Here we summarized some solutions for such issues.

    1. Clean the heat sink to ensure tight contact between the IGBT and the heat sink.

    2. Clean the fan, including the fan blades and lubricate the bearings if needed.

    3. Clear the airflow path of the fan.

    4. Replace with higher power IGBTs, ensuring the withstand voltage is not lower than the original IGBT’s value.

    Above all are the information that we’d shared, welcome to contact us if you want to know more. Best Technology is a historic company which has over 17 years PCB manufacturing experience, here you can enjoy the one-stop ODM & OEM service, one-to-one after sales, quick delivery and high-quality products.

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