High current management

High currents of up to several hundred amperes in PCBs are nothing unusual. Nevertheless, in order to ensure that optimum functionality of the power electronics is obtained, a large amount of copper in the right places on the PCB is required. We have the right technology for your high-current application.

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High current management

Your benefits

Control and power electronics on the same board
Targeted partial increase in cross-section for high-current paths
Minimisation of space requirements for high-current conductors
High current in combination with 3D installation geometries
Reduction of overall costs (logistics, procurement, assembly, quality assurance)
Design support and calculation of current paths

We are happy to support your project at every step along the way.
Contact our expert team here.

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Nowadays, high currents of up to several hundred amperes are nothing unusual. Nevertheless, in order to ensure that optimum functionality of the power electronics is obtained, a large amount of copper in the right places on the PCB is required. At the same, fine conductor structures need to be placed on a PCB for control tasks. With our wide choice of technologies for thick copper PCBs, we can offer a reliable basis for power electronics requirements – to suit your particular project. Our extensive product portfolio covers high-current-only PCBs as well as combined power and control electronics boards. Additional functions such as 3D designs increase functionalities and application possibilities.

Power distribution/fuses for tracked vehicle

Structure	Thick copper, 8 copper layers
Material	FR4 – Isola DE104 (TG≈135 °C)
PCB thickness	2,8 mm
Circuit board technology	Iceberg®, through-connection, line/space: 250/230 µm
Surface	Chemical tin
Special features	Combined outer layer layout with 50µm and 400µm copper thickness, via filling type III-a

Electric vehicles

Structure	4-layer multilayer, 70µm copper thickness
Material	FR4 TG150°C Panasonic R-1566W
PCB thickness	1.6 mm
Circuit board technology	HSMtec®, 8 and 12mm wide internal copper profile
Surface	Chemical Ni/Au
Special features	Copper profiles for 220A current flow and for heat dissipation to heat sink on back of board

Motor controller for fan cooling

Structure	4-layer multilayer, 70µm copper thickness
Material	FR4 TG150°C Panasonic R-1566W
PCB thickness	1.7 mm
Circuit board technology	12mm, 8mm and 2mm wide copper profiles on an inner layer and an outer layer for 60 and 15 amperes
Special features	Eight half-bridges have to be connected to the connectors by 4x15A = 60A conductors. Heat dissipation from the half-bridges has to be carried via a bending edge to a PCB tab that is glued to an aluminium heat sink in the casing

Optimising high-current circuit boards for motor controllers: Technical article from Elektronik Praxis

When designing and producing a high-current PCB there is an enormous number of parameters to take into account. That is why we advise you to talk to us at a very early stage of development. Through our online advice service or on-site workshops we can discuss the technical aspects and special considerations that such PCB types involve right from the start. We are also happy to help you with technical optimisation features or cost-reduction measures.

Simply make an appointment by e-mail right now:
power@ksg-pcb.com

PCB technologies for high current

[Translate to English (us-en):] Anschliff einer Dickkupfer-Leiterplatte

Thick copper

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Iceberg®

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HSMtec®

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Design guidelines for PCBs

Which important parameters do you need to successfully create a layout for a project? We’ve combined all of the parameters for you in our PCB Design Compass