pcb technology for high currents

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 History

1923

1980s

1960s 1950s

Today

History

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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