#copper laminated flexible connectors

[bajeria]

Copper Laminated | Bajeria Industries

We manufacture air cooled connectors, braided copper tapes, round standard copper cables, earthing tapes & ropes. These highly flexible connectors are manufactured by using copper wire of any diameter as per requirement. The above copper connectors are made from bare, tined and silver plated copper. The contact areas are assembled with pressed copper connectors, bare and on request tin or silver coated. Hot tinned dipped ends can also be provided to give perfect conductivity. We manufacture connectors in any width and cross section upto 10000 sq. mm. The high flexibility offers installation into difficult and small places. We Bajeria is specialized in manufacturing, Copper Laminated Flexible Connectors .We offer complete customized solutions to our customers depending upon their exact requirements.

[cynthia-hitechpcba]

Different kinds of Aluminum PCBs

Flexible Aluminum PCBs

One of the newest developments in IMS materials is flexible dielectrics. These materials feature a polyimide resin system with ceramic fillers which provides excellent electrical insulation, flexibility and of course thermal conductivity. When applied to a flexible aluminum material like 5754 or similar, the product can be formed to achieve a variety of shapes and angles which can eliminate costly fixtures, cables and connectors. Although these materials are flexible, they are intended to be bent into place and remain in place. They are not suited for applications that are intended to be flexed regularly.

Hybrid Aluminum PCBs 

In a ‘Hybrid’ IMS construction a “Sub-assembly” of a non-thermal material is processed independently and then bonded to the aluminum base with thermal materials. The most common construction is a 2-Layer or 4-Layer Sub-assembly made from conventional FR-4. Bonding this layer to an aluminum base with thermal dielectrics can help��dissipate heat, improve rigidity and act as a shield. Other benefits include:

Less costly than a construction of all thermally conductive materials

Provides superior thermal performance over a standard FR-4 product 

Can eliminate costly heat sinks and associated assembly steps 

Can be used in RF applications where a surface layer of PTFE is desired for its’ loss characteristics.  

Use of component windows in the aluminum to accommodate through-hole components. This allows connectors and cables to pass connections through the substrate while the solder fillet creates a seal without the need for special gaskets or other costly adapters. 

Multilayer Aluminum PCBs

 Common in the high performance power supply market, multilayer IMS PCBs are made from multiple layers of thermally conductive dielectrics. These constructions have one or more layers of circuitry buried in the dielectric with blind vias acting as either thermal vias or signal vias. While more expensive and less efficient at transferring heat as a single layer designs, they provide a simple and effective solution for heat dissipation in more complex designs. 

Through-Hole Aluminum PCBs

In the most complex constructions a layer of aluminum can form a ‘Core’ of a multilayer thermal construction. The aluminum is pre-drilled and back-filled with dielectric prior to lamination. Thermal materials or sub-assemblies can be laminated to both sides of the aluminum using thermal bonding materials. Once laminated, the completed assembly is thru-drilled similar to a conventional multilayer PCB. The plated through holes pass through the clearances in the aluminum to maintain electrical insulation. Alternatively a Copper core can allow both direct electrical connections as well as with insulated through holes. 

If you want to know ceramic PCBs, please feel freely to contact Cynthia at sales11@hitechpcb.com

[qocsuing]

Harnessing the Power of Innovation: A Spotlight on FFC Cable Manufacturers

Harnessing the Power of Innovation: A Spotlight on FFC Cable Manufacturers In the world of electronics, the unsung heroes are often the components that provide the vital links between various parts of a system. One such component is the Flat Flexible Cable (FFC). FFCs are used in a wide range of applications, from automotive systems to consumer electronics, and are produced by specialized manufacturers known as FFC Cable Manufacturers.Get more news about Ffc Cable Manufacturer,you can vist our website!

FFC Cable Manufacturers are at the forefront of technological innovation. They produce cables that are not only flexible and thin but also capable of transmitting data at high speeds. This combination of flexibility and performance has made FFCs indispensable in modern electronic devices.

The manufacturing process of FFCs is a complex one. It involves precise engineering and stringent quality control measures to ensure that each cable meets the required standards. The process begins with the selection of materials. The conductive cores of FFCs are typically made from tinned copper, which is known for its excellent electrical conductivity.

Once the materials are selected, they are processed into flat, thin strips. These strips are then laminated together to form a flat cable. The ends of the cable are then terminated with connectors, which allow the cable to be plugged into electronic devices.

Quality control is a crucial aspect of FFC manufacturing. Each cable is thoroughly tested to ensure it meets the required electrical and mechanical specifications. This includes tests for resistance, capacitance, and tensile strength.

In conclusion, FFC Cable Manufacturers play a crucial role in the electronics industry. Their commitment to innovation and quality ensures that we can enjoy the benefits of modern electronic devices. As technology continues to advance, we can expect these manufacturers to continue pushing the boundaries of what is possible with flat flexible cables.

[mogood]

Heavy Copper PCB: Power Up Your Electronics with Thick Copper Boards

When it comes to powering up electronics, one of the most important components is the Printed Circuit Board (PCB). And when it comes to heavy-duty applications that require high power, thick copper PCBs are the way to go. These specialized boards are designed to handle larger currents and dissipate heat more efficiently than standard PCBs.

One popular type of heavy copper PCB is made from FR4, a type of fiberglass-reinforced epoxy laminate. With a board thickness of 1.6mm, these boards can handle current levels ranging from 2 to 12oz, making them ideal for a wide range of applications.

To ensure reliable performance and longevity, the boards are surface-treated with immersion gold. This coating protects against corrosion and helps ensure good conductivity.

When it comes to payment and delivery terms, customers have a variety of options. Payment can be made through L/C, T/T, or WesternUnion. Delivery terms include DDU, FOB, CFA, CIF, CPT, and EXW. This flexibility makes it easy for customers to find a payment and delivery arrangement that suits their needs.

In terms of certifications, these heavy copper PCBs have been tested and certified for use in a wide range of applications. They meet UL Consumer (Wear, Electronic Digital, Household Appliances, Connectors), Industrial Control, Automobile TS16949, Medical, Server, Cloud Computing & Base Station, Aviation, Military, and Communication standards. This means that they are suitable for use in everything from household appliances to military equipment.

In conclusion, if you need a PCB that can handle heavy-duty power applications, look no further than heavy copper PCBs. With their FR4 material, 1.6mm thickness, and surface treatment of immersion gold, these boards are designed for reliable performance and longevity. And with a range of payment and delivery options, they are easy to acquire and integrate into your project.

[rajasthanelectricwire-blog]

Since the time of its discovery, copper wires have played a dominant role in various ways in the human life. Its usage has only been increasing in most of the industries. Copper is applied in numerous ways.

[ganpatiengineeringwires]

Laminated copper flexible connectors are produced from high conductivity electrolytic grade copper foils sheets. They are utilized in switchgear industries, power plants, cathodic protection, transformers, etc. they are endurable and long-lasting, and easy to use.

[pcbsmart]

Features of a PCB board

A two-layer PCB board is considered the simplest way to produce. These boards feature a copper layer on both of their sides as outer layers. Boards that have multiple layers will usually have a sandwich of extra interior copper layers as well as the required insulation to protect the circuits from surge voltages.

After a two-layer PCB, the next most convenient and easiest way to produce is the four-layer board. These electronic circuit boards are capable of adding a considerable amount of routing options in the inside layers when compared to those of two-layer boards. Some piece of these inside layers is suitable to use as a power plane or ground plane.

The reason for using some inside layers as a power plane or ground plane in a printed circuit board is to attain the following benefits, such as:

Improved signal integrity

Lower EMI

Higher signaling frequencies

Enhanced power supply decoupling

Through Hole components in a circuit board are mounted by the wire leads, which are passing through it. They are soldered to outlines on the other side of the board. Surface mount components of the board are connected to their leads to copper outlines on the same side of the board. A printed circuit board may use both techniques for mounting electronic components.

In PCB manufacturing, most companies do not prefer to use the Through Hole method during their manufacturing process. Most manufacturers use only Surface Mount method for mounting various electronic components, including:

Diodes

Transistors

IC chips

Capacitors

Resistors

However, they use this method to mount some large electronic components, like electrolytic connectors and capacitors.

Artwork is a pattern, which is used to etch into each copper layer of a printed circuit board. Manufacturers use photoresists to etch a circuit board, and layer onto it. The light is then projected to the etched part of the board in the artwork pattern.

The opposed material will safeguard the copper PCB printing from closure into the etching solution. The etched circuit board is then sanitized and cleaned. In boards that contain multiple layers, the material layers are laminated jointly in an alternating sandwich, such as copper, substrate, etc. The external layers of the board are only to be coated, as the nearby substrate layers will protect the inside copper layers.

All types of printed circuit boards will undergo a PCB prototype process before their manufacturing process. This is for the reason that it will aid manufacturers to find out a variety of flaws effectively. If you are designing a circuit board, the process will aid you considerably in having a performance-centric board.

The lights in an LED PCB will also need a circuit board because it plays a vital role in supporting LED lighting. It backs the LEDs physically by conducting heat from the LED bulbs. It, in turn, improves the performance of the bulbs, in addition to inhibiting them from excess heating.

A Rigid Flex PCB is largely used in industrial, commercial, and martial applications. They are also used in a variety of devices, ranging from cell phones to digital cameras to smart devices,. As these PCBs are frivolous in design, they are used to make pacemakers in the medical industry because of their space-saving and flexible design, as well.

[ultrajack666-blog]

Optimize High Current PCB for Motor Controls

If you want to control currents for electrical drives and power supplies with intelligent electronics, you have to master the balancing act between power and microelectronics. This article describes different variants of a unique and diverse high current PCB technology that are suitable for currents up to 1,000 A. At the heart of this technology are embedded copper bars that protrude from the surface to contact SMDs and other power components.

In order to close the gap between high-current conductors on the one hand and electronic components on the other, a number of cables, mounting materials, and interposers are usually required, especially if SMDs are provided. The aim is to integrate busbars in printed circuit boards in order to save construction volume and assembly effort for systems and to combine the drive and supply currents as well as electronic controls.

There are a number of circuit board technologies that are designed for power applications. These include multilayers with increased copper layer thicknesses of up to 400 micrometers, which can be leveled at higher layers. In addition, several techniques are offered that rely on a selective increase in the copper cross-section, such as the iceberg technique, the wire laid technique and the partial embedding of thick copper laminates.

Drive technology: Optimize high current PCB for motor controls

Three PCB technologies for high-current circuit boards are compared in this article: Dickschicht, Iceberg, and HSMtec. PCB topology and PCB design influence the current carrying capacity and heat dissipation of the power semiconductors.

Suitable technologies are available for combining the load circuit and fine conductor for logic signals on an FR4 circuit board. You save space and avoid the conventional connection technology with separate boards, which increases the reliability of the motor control. The PCB developer can optimize the current carrying capacity and heat dissipation of the power semiconductors according to his task.

From the point of view of the printed circuit board, the specifications of the drive electronics can be summarized in five points: 1) high integration density, 2) reliability of the electronic assembly, 3) fast heat dissipation, 4) high currents combined with control electronics and 5) reduced system costs, e.g. by switching to SMD components, fewer components or assembly processes.

A smart solution is to combine the power section and the control electronics, i.e. the load circuits and the control logic, instead of on two circuit boards on just one circuit board. However, this requires large conductor cross-sections and large insulation distances for the high-current conductors and, at the same time, fine conductor structures for the control on one and the same board. This eliminates expensive plug connections, cables, and busbars, as well as assembly steps and risks that limit reliability. The PCB specialist KSG has three technologies for this: thick copper, iceberg and HSMtec technology. All three processes use the standard base material FR4.

Safe contact with high current PCB

All of these technologies have something in common: There is usually not a sufficient cross-section between the layers of the high current PCB board and the connections for surface-mounted components or screw connections. The vias form a bottleneck for the currents of the desired size. And the press-in plugs, screws, and clamps also do not guarantee reliable contact with the layers. Only the clean soldering of connections forms a continuous connection from the components to all layers. Here, however, the higher the total copper thickness, the riskier is the solder penetration.

In contrast, regardless of the design, the high-current circuit board contacts the components and connections with the maximum conductor cross-section (Figure 2 below). In this way, SM and THT components can be combined with bonded power semiconductors, press-in contacts and screw connections without a bottleneck in the current path. At the same time, the busbar serves as a heat sink. The components are in direct contact with this thermal mass and are therefore optimally cooled.

Design, production, and processing of high current PCB

Compared to conventional busbars known from electrical engineering, individually shaped copper parts are used for the high-current circuit board. The shape and position of the copper parts can be freely defined. This gives the layout designer the freedom to place the components and connections in such a way that a compact module with optimized thermal and electrical functions is created.

Since each high-current project has its own characteristics, it is difficult to lay down general design rules. Depending on the size and shape of the copper parts and insulation bars, the design limits for each project must be checked. Guideline values ​​provide a rough guide for the design.

To manufacture a high current PCB circuit board, the copper parts are first manufactured. Depending on the size, shape, and number of parts, this is done by etching, milling or punching. The copper parts are placed in pre-milled frames and then pressed with prepregs and possibly other layers.

One advantage of the high current PCB is the processing. Because the busbars are embedded, the high-current circuit board – apart from its weight – cannot be distinguished externally from other circuit boards. It can be processed in conventional SMD processes if the profile is set to the higher thermal mass. Experience shows that these soldering processes can be mastered well. A repair process for components that come into direct contact with the high-current rail, on the other hand, is more complex than with conventional flat assemblies.

Technology variants of high current PCB

The full potential of the high current PCB board becomes clear when you consider the possible variations.

The technology offers the greatest benefit if the copper parts are shaped in such a way that they reach the surface and are flush with the other pads on TOP and / or BOT (Fig. 1). This gives you a completely flat circuit board that can be further processed in the subsequent paste printing and assembly process without adjustment. Cable lugs, modules, and screwable components are also easier to connect to the high-current position.

In another version of the technology, the high current layer protrudes laterally from the edge of the circuit board. These contacts can be used directly as plugs or can be contacted like the end of a conventional busbar.

The next two variants of the high current PCB circuit board aimless at high currents than at cooling components.

If the copper parts have SMD connection surfaces both upwards and downwards, they work like conventional printed circuit board inlays, which are pressed into the cutouts in printed circuit boards to conduct heat from power components from TOP to BOT. The embedded copper parts (Fig. 9) differ from conventional inlays in that they are more reliable in manufacture and processing since there is no mechanical stress on the circuit board. In addition, the size and position of the pads can be selected independently of one another. An electrical connection is also possible without additional effort.

The last variant of the high current PCB board is a one-sided version (Figures 10 and 11). Here, raised pads of copper sheet protrude through the insulation of a thin insulation layer, in order to then be contacted directly as SMD heatsink contacts to the corresponding component connections. In contrast to aluminum substrates made from IMS, this version does not have an insulation layer, so that significantly higher powers can be dissipated here. Such constructions are used, among other things, for high-performance LEDs with up to 10 W.

With the high-current circuit board, MOKO Technology is expanding its range of technologies in the field of thermal management with another important component:

Solid copper is embedded in the circuit board and can be fitted directly to SMD pads that reach the surface.

Structure of an SMD high-current circuit board

The high current circuit board can also be contacted with other assembly and connection technologies:

– Reflow / wave soldering SMD / THT – Aluminum wire bonding – Screws: eyelets / threaded holes – Blind holes from the outer layers – Press-fit technology high current connector

In many cases, the additional effort for the production of high current PCB can be reduced partly through specially implemented manufacturing processes and partly through optimized process control of standard processes.

Thick copper PCBs distribute the power losses horizontally

Thick copper technology has been established on the market for many years and is manufactured in large quantities. The PCB industry usually speaks of thick copper for copper structures of ≥105 µm. Thick copper conductors serve the better horizontal heat distribution of high power losses from power components and/or for the transport of high currents and replace stamped and bent constructions for busbars in high current PCB applications. With up to four inner layers, each with 400 µm copper, a current-carrying capacity of several hundred amperes is possible. Ideally, the thick copper conductors are located in the inner layers.

Flexibility for changes in the layout, the compact design, simple processing/assembly and comparably low change costs as well as the standard processes of the PCB industry speak in favor of the thick copper PCB. Although the process steps of a thick copper circuit board do not differ significantly from the standard throughput of a conventional circuit board, the production requires special process experience and management. A thick copper circuit board stays in the etching line 10 to 15 times longer and has a typical etching profile. The etching and drilling processes of the thick copper circuit board determine the design rules for the circuit diagram and must be observed. The PCB manufacturer has a list of suggestions for cost and process-optimized layer construction and design rules.

Important to know: FR4 laminates with a base copper cladding ≥105 µm are more expensive due to the high copper content. Compared to a standard laminate laminated on both sides with 18 µm, the material cost factor is around 1: 8 to 1:10. The PCB developer must pay attention to maximum material utilization. Early coordination with the PCB manufacturer helps to significantly reduce costs. With regard to miniaturization, thick copper technology is limited. Due to the strong undercut, only relatively coarse structures can be created. Another limitation: fine signal wiring is not possible on the same wiring level as the thick copper conductor.

Iceberg: for a uniform surface topography

In a wiring level, there are areas with 70 to 100 µm copper for the logic and areas with up to 400 µm copper for the load. The thick copper is largely sunk in the circuit board. This creates a uniform surface topography across the entire conductor pattern. The iceberg principle can also be combined with thick copper on the inner layers.

Embedding two-thirds of the 400 µm thick copper area in the base material creates a planar printed circuit board surface. Advantage: The conductor flanks can be reliably covered with a solder mask in just one casting process. The subsequent assembly process is possible on one level. Iceberg structures are also suitable as heat sinks for power components and can be combined with plated-through holes (vias) to optimize thermal management.

HSMtec: copper elements in the inner and outer layers Another way to combine load and logic on a circuit board is HSMtec. Here, massive copper elements are selectively installed in the inner layers and under the outer layers of the FR4 multilayer at those points where high currents flow, and ultrasonically bonded to the base copper of the etched conductor patterns. After pressing the layers, the copper profiles are located under the outer layers and/or in the inner layers of the multilayer. The rest of the circuit board remains unaffected.

The multilayer is manufactured in the standard manufacturing process and further processed in the usual assembly and soldering process. With this structure, the electrical specifications for the dielectric strength and insulation classes of machines can be served as well as demanding temperature conditions with limited installation space in vehicles.

The solid copper profiles inside the multilayer also enable three-dimensional constructions. Notch milling perpendicular to the copper profiles allows segments of the circuit board to be bent up to 90 °. In this way, installation space is cleverly used and high current and heat are transported over the bending edge. The construction is laid out as a two-dimensional circuit board, manufactured and assembled in the panel. After assembling or assembling the module, the circuit board is bent into the three-dimensional shape.

Software supports the developers in dimensioning high-current conductor tracks. With just a few entries such as current and temperature, the calculator provides the minimum wire width for HSMtec as well as for 70 and 105 µm copper cladding.

[bajeria]

Copper Flexible | Bajeria Industries

We Bajeria is specialized in manufacturing, Tinned Copper Braided Flexible Jumpers. We offer complete customized solutions to our customers depending upon their exact requirements. For more information please kindly visit our website https://www.bajeria.com/copper-braided-flexible-jumpers.html

[theabsolutepcba]

Get to know a little about Aluminium PCB

Aluminium printed circuit boards contain a thin layer of thermally conductive dielectric material that transfers heat

There are many names for these products; Aluminum clad, aluminium base, metal clad printed circuit board (MCPCB), an insulated metal substrate (IMS or IMPCB), thermally conductive circuit boards, etc. ... but they all mean the same thing and work in the same way.

How are aluminium PCBs made? A thin layer of thermally conductive but electrically insulating dielectric is laminated between a metal base and a copper foil. The copper foil is etched into the desired switching pattern and the metal base draws heat away from this circuit through the thin dielectric.

Advantages of aluminium PCBs Heat dissipation is dramatically better than standard FR-4 constructions.

The dielectrics used are typically 5 to 10 times as thermally conductive as conventional epoxy glass and one-tenth of the thickness

Thermal transfer is exponentially more efficient than a conventional rigid PCB.

Lower copper weights than suggested by the IPC heating charts can be used.

Applications of aluminium PCBs Although Power Converters and LEDs are the largest users of these products, Automotive and RF companies also want to reap the benefits of these constructions. Although a single layer construction is the simplest, Amitron has other configuration options, including:

Flexible aluminium PCBs One of the newest developments in IMS materials is flexible dielectrics in PCB assembly Chicago. These materials are equipped with a polyimide resin system with ceramic fillers that offers excellent electrical insulation, flexibility and natural thermal conductivity. When applied to a flexible aluminium material such as 5754 or similar, the product can be moulded to obtain a variety of shapes and angles that can eliminate expensive fixtures, cables and connectors. Although these materials are flexible, they are meant to be bent and stay in place. They are not suitable for applications that are intended to be bent regularly.

Hybrid aluminium PCB's In a 'hybrid' IMS construction, a 'sub-assembly' of a non-thermal material is independently and subsequently processed bound to the aluminium base with thermal materials. The most common construction is a sub-assembly with two or four layers made from conventional FR-4. By attaching this layer to an aluminium base with thermal dielectrics, heat can be dissipated, stiffness is improved and it can act as a shield. Other benefits are:

Less expensive than a construction made of all heat-conducting materials

Offers superior thermal performance over a standard FR-4 product  

Can eliminate expensive heat sinks and associated assembly steps

Can be used in RF applications where a PTFE surface layer is desired due to the loss characteristics.

Use of component windows in the aluminium to accommodate components with through holes. This allows connectors and cables to pass connections through the substrate while the solder hook creates a seal without special gaskets or other expensive adapters.  

There are many workplaces for PCB assembly Chicago to visit and get your work done. Visit today to know more about the newest in the field of electronics.

Also read: Know how to design a circuit board at home

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[qocsuing]

What are FFC (flat flexible cables)?

What are FFC (flat flexible cables)?

FFC (flat flexible cable) is a ribbon-type cable used to connect PCBs. It is typically used in laptops, cellphones, and other high-density electronic applications. FPC (flexible printed circuit) is sometimes used to refer to FFCs, but one important difference is that FPCs incorporate components, while FFCs are typically straight connections without components.Get more news about Ffc Cable Manufacturer,you can vist our website!

FFCs became the PCB standard interface in the 1970s. The cable consists of a plastic film that contains multiple flat metallic conductors bonded to one surface. Thin rectangular copper conductors are laminated between two layers of polyester insulation. Each end of the conductors is left uncovered and then tin plated to make electrical contact with the connector. The ends of the cable are sometimes reinforced with a stiffener for easy insertion or strain relief. This makes the cable slightly thicker at the ends.

FFCs are suited to high-flex applications because they often take up less space, offer greater flexibility, and are more flexible than round cables, which are wrapped by different materials. The wires in FFC are protected individually.

Initially, termination technology was either direct solder (a permanent connection for low-cost applications) or crimped contacts (a separable connection for high-end pluggability). ELCO developed the first card edge style connector in 1986 to mate directly to the FFC. This low insertion force (LIF) type connector provided simple and reliable mating and unmating of the cable to the printed circuit board. ELCO’s 8370 Series became an industry standard for cost-effective FFC terminations. In 1987, ELCO introduced the first zero insertion force (ZIF) connector, Series 6200, which provided increased mating and unmating cycles.

The number of conductors (pins) can range from just a few to more than 100. Pitch – Many pitches are available, but the most common are 0.500 mm, 1.00 mm, and 1.25 mm. Custom pitch and multiple pitch FFC may also be available. Type – Some cables (described as Type 1 by Würth Elektronik or Type A by Molex) have the exposed contacts on the same side at each end. Other cables (labeled Type 2 or Type D) have the exposed contacts on opposite sides of the cable. Exposure length refers to the length of the electrical contact exposed at that termination of the cable. Stiffener – Extra material attached on the opposite side of the exposed length of the cable to facilitate ZIF or LIF.

[rajasthanelectricwire-blog]

Rajasthan Electric Industries manufactures copper laminated flexible connectors by applying high current pressure on stacks of electrolytic copper.  The connectors are vastly used in various applications such as power plants, electric locomotives, bus ducts, transformers, Galvano engineering, furnaces and similar. We offer customized services specific to your needs.

[ganpatiengineeringwires]

Laminated Copper Flexible Connectors

Laminated copper flexible connectors are produced from high conductivity electrolytic grade copper foils sheets. They are utilized in switchgear industries, power plants, cathodic protection, transformers, etc. they are endurable and long-lasting, and easy to use.

[subzerosol]

We  Bajeria expertise in manufacturing, exporting and supplying flexible copper connectors of both braided and laminated types. We offer complete customized solutions to our customers depending upon their exact requirements.