pcb technology for high currents
TRANSCRIPT
Components for 232Amp on your PCB, how do you do it?
Georg Grunenberg
• Introduction of Phoenix Contact
• PCB technology for 232 Amp
• Customer benefit
• Questions
Topics
Corporate Principles
Mission
We create progress
with innovative and inspiring solutions.
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PCB technology for high currents
Copperfoils for PCB´s (layermaterial)
Which typs are available, and which are suitable
5 µm
9 µm
12 µm ( = 1/3 ounce/ ft²)
18 µm ( = ½ ounce / ft²)
35 µm ( = 1 ounce / ft²)
70 µm ( = 2 ounce / ft²)
105 µm ( = 3 ounce/ ft²)
140 µm ( = 4 ounce / ft²)
210 µm ( = 6 ounce / ft²)
400 µm
PCB technology for high currents
Suitable for inner
layers for high
currents
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Standard
PCB technology for high currents
Selective Heavy Copper
High Current
Thick Copper PCB
Inner Layers up to 400 µm
Outer Layers up to 210 µm
Iceberg technology
• Inner Layers
up to 400 µm
• Outer Layers
up to 400 µm
Wirelaid technology
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PCB technology for high currents
Example for a Multilayer PCB
Pad
Outer Layer
(up to 105 µm copper foils)
Inner Layers
(up to 400 µm copper foils)
Core Material (FR 4)
Prepeg
(e.g. FR 4)
Prepeg: flame retardant compound material, FR4
Core Material: pressed Prepeg between 2 copper foils…
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Microsection of a 6-layer Multilayer PCB
Source: Schweizer AG
PCB technology for high currents
Outer Layer
(up to 105 µm
copper foils)
Inner Layers
(up to 400 µm copper foils)
Core Material (FR 4)
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There are different kinds of thermal pads in the inner- and outerlayers.
Vias (drilled holes) are recommended due to a better thermal behaviour, they will
be filled during the soldering, but they reduce the cooling of the component / the
soldering pins.
PCB technology for high currents
direct link to the copper layers
Additional drilling holes (Vias)
with 0,8 mm diameter as
Heat trap (recommended)
4,8 mm
Note: The layout of the PCB has to be defined by the customer in
dependence of the application.
Ø 0,8 mm
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PCB technology for high currents
+
Multilayer PCB
MKDSP 95
PCB thickness: max. 2,7 mm
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PCB technology for high currents
PCB top side Temp.:
Wave Temp. :
Real example for a soldering process with Ersa Powerflow:
Note: The diagram is only an
example, it works also with
shorter preheating.
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PCB technology for high currents MKDSP 95 with Multilayer PCB
PCB Layout for 232 A permanent
(example PCB)
Number of layers thickness Width of track
Outer layer 2x 105 µm 14,5 mm
Inner Layer 4x 400 µm 27,5 mm
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PCB technology for high currents MKDSP 95 with Multilayer PCB
Results with permanent test current 232 A
The measured temperature of the PCB is 60°C, the ambient
Temperature was 22°C. This results a temperature rise of 38 K.
Temperature rise in Kelvin [K]
Test current
150 A 180 A 232 A
18 K 24 K 38 K
Note: Most customers don´t need 232 A permanently, but big conductor size for
their devices. The maximum conductor size for the MKDSP 95 is 95 mm² with
ferrule!
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PCB technology for high currents MKDSP 95 with PCB
0
40
80
120
160
200
240
280
320
360
400
440
0 10 20 30 40 50 60 70 80 90 100 110
cu
rre
nt (A
)
Ambient temperature (°C)
MKDSP 95 with PCB
Current rating curve
Number of position: 4
Deratingfactor = 1
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Worldwide unique
Replacement for copper bars
35% cost reduction
80% less parts
New Design with High Current PCB for power electronics
Actual design New design with
MKDSP 95
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Frequency converter conventional
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PM 240 – 2 „FSE“
Line:
MKDSP 95 / 4 - 20 DC Bus:
MKDSP 95 / 2 - 20
Motor Connection:
MKDSP 95 / 4 - 20
Braking Resistor:
MKDSP 25 / 3 - 15
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PCB technology for high currents MKDS(P) Series
MKDS 5N • 41 A
• 1000 V (IEC)
• 4 mm²
MKDSP 10 • 76 A
• 1000 V (IEC)
• 16 mm²
MKDSP 25 • 125 A
• 1000 V (IEC)
• 35 mm²
MKDSP 50 • 150 A
• 1000 V (IEC)
• 50 mm²
MKDSP 95 • 232 A
• 1000 V (IEC)
• 95 mm²
Complete Range up to 232 A
232 A through a PCB No Problem!
new
new
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Questions ?
PCB technology for high currents
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Thank You !
PCB technology for high currents
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PCB technology for high currents
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