Basic parameters of a thick film ceramic plate
- Thickness: Thick film ceramic plates have 0.64 mm thickness, but can be created in different thickness values from 0.32 mm to 1.27 mm.
- Dimensions: Thick film ceramic plates come in different size values that are from 10 mm x 10 mm to 300 mm x 300 mm.
- Material: It is created with alumina, but can also be created with other materials like magnesia, beryllia, and titania.
- Surface finish: It has a smooth surface finish that can also be textured or etched.
- Electrical properties: it has a high-dielectric constant and less resistivity, so it is preferred to use in capacitors and resistors.
- Mechanical properties: These plates are strong and durable, so used in harsh environments.
- Chemical properties: These boards are inert and non-reactive, making them a fine solution to use in applications where corrosion is a issue.
Design and manufacture of thick film ceramic PCB
- Define the requirements: The first is to define the needs for PCB boards. That are board types, the number of layers required, the board size, and the environmental conditions that the board will be exposed to.
- Create a circuit diagram: After defining the requirements circuit diagram is made. The circuit diagram shows the component’s layout on board and the connection of these components
- Generate a Gerber file: With the use of a circuit diagram Gerber file is made. it is a set of files that have the information required for board manufacturing.
- Choose a substrate: In this step, the PCB substrate is selected. There are different types of substrates each has different parameters
- Specify the inks: The ink which has to use for circuit printing on the substrate also must be specified
- Design the solder mask: The solder mask is the material’s layer that is applied on the board to protect copper conductors from solder
- Design the fiducial marks: Fiducial marks are small, raised markers that are used for board alignments during the production process
- Generate a 3D model: A 3D model of the board produced that help to visualize the design and to check for interference.
The manufacturing process of Thick Film Ceramic PCB
The first step in the production process is to prepare the ceramic substrate. The substrate is etched to make a project-required pattern
In this phase, ink is applied to the substrate. It is done with the use of a screen printing process. Screen used to creation of stencil of pattern required
Heat gun or oven used to dry the inks. This stage is significant to confirm that inks are accurately cured
The last step is to fire the substrate. it is done in an oven at a high temperature. The firing process cures the inks and bonds them to the substrate.
The finished board is inspected for defects. Different methods such as visual inspection and electrical testing are used
Application of thick film ceramic PCB
- Military and aerospace equipment: These boards are used in military and aerospace devices since they are reliable and has the ability to handle high temperature.
- Industrial control systems: This PCB is also used in industrial control systems since it is smaller and can be designed to handle harsh environments. Power plants, factories, and oil rigs are common example that uses these boards
- Medical devices: These PCBs are part of medical instruments since has the ability to withstand the sterilization process. Defibrillators, Pacemakers, and MRI machines use these boards
- Telecommunications equipment: It is part of telecommunications instruments since they are small and can be made to withstand high frequencies. Products that use these boards are mobile phones, computers, and routers.
- Consumer electronics: These boards are also employed in different consumer electronics since they are smaller in size and can be created to withstand the heat produced by these devices. Examples of products that use these PCBs are TVs, LCDs LEds.
Advantages of Thick Film Ceramic PCB
High Thermal Conductivity
Due to ceramic materials’ excellent thermal conductivity, thick-layer ceramic boards excel in thermal management. By effectively dissipating heat generated by components, the ceramic substrate lowers the possibility of thermal damage and ensures peak performance.
Excellent Electrical Insulation
Outstanding electrical insulation capabilities are provided by the ceramic material’s thick insulating layer. It is best for HF systems because it reduces signal interference, provides good signal integrity, and minimizes the chances of short circuits.
Comparison with Other PCB Technologies
Feature Thick Film Ceramic PCB Single-Layer PCB Multi-Layer PCB Rigid-Flex PCB Material Ceramic FR4 FR4 FR4 Number of layers 1 1 2-20 1-20 Cost High Low Medium Medium Reliability High Medium Medium High Size Small Small Large Large Weight Light Light Heavy Heavy Temperature range -55°C to 300°C -55°C to 105°C -55°C to 105°C -55°C to 150°C Applications Military devices, industrial control systems, medical devices, telecom sectors, consumer electronics low-power devices Consumer electronics, PCs, power supplies networking equipment, Automotive, aerospace medical devices,
- Thick Film Ceramic PCB vs. Metal Core PCB: The flexibility to incorporate components directly onto the substrate, increased thermal conductivity and improved electrical insulation are all benefits of this board over metal core PCBs for thermal management.
PCBONLINE: High-Quality Ceramic PCB Manufacturer
One of the top producers of ceramic printed circuit boards, PCBONLINE, primarily uses 3D-DPC technology. Additionally accessible for ceramic PCB creation at PCBONLINE are HTCC, LTCC, DBC, and AMB. IGBT modules, COB LED modules, ceramic LED plates, aluminum nitride PCBs, SiC PCBs, PCB assembly, and box-build assembly are all offered by PCBONLINE as ceramic PCBs.
Here are some explanations for using PCBONLINE as your go-to source for ceramic PCB production:
- The circuit layer’s copper thickness may be freely modified to be between 100nm and 300m.
- High-density and three-dimensional designs are both possible.
- improved temperature resistance and weld performance.
- The circuit layer has a longer shelf life and doesn’t have an oxide layer.
- A ceramic PCB can only be as big as 138mm by 190mm. The maximum dimension for extreme prototypes is 160mm by 280mm. (Please allow a 4–5 mm space between the edge rails.)
- Available ceramic thickness ranges from 0.15 mm to 4.0 mm. (The PCB is 0.1 mm thicker than the ceramic.)
- Personalized engineering assistance for the duration of your project and a free sample for mass manufacturing.
Thick Film Ceramic PCB Technical Features
- Compact Size and High Component Density: This PCB has the benefit of compact size without making changes in the density of components. As it has a multi-layered structure that helps for integrating a large number of components in less space so it is best for applications where space is limited
- Durability and Reliability: These pcb boards are known for their durability and reliability. They can also withstand harsh conditions like high temperatures, and mechanical stress, and make sure long-term operation, and decrease the risk of damaging
- Compatibility with Various Electronic Components: These boards are compatible with different types of discrete, integrated, and resistive electronic parts, as well as capacitors, and resistors. and ICs. They are appropriate for a variety of electronic systems and applications because of their adaptability.
- Customizable Design Options: Design freedom is offered by these boards. They may be tailored to satisfy certain needs, such as particular measurements, intricate electronics, and unique functionality. This adaptability enables customized solutions for different application requirements.
- Wide Operating Temperature Range: Thick sheet ceramic boards are best for applications that require the ability to function properly across a wide temperature range. This quality guarantees operation and stability even in difficult heat settings.
- Compatibility with High-Frequency Signals: This PCB is ideal for high-frequency applications because of its good electrical characteristics. They ensure dependable high-frequency signal transmission by reducing signal losses, distortions, and crosstalk.
- Solderability and RoHS Compliance: Thick film ceramic boards have strong solderability, which enables them to be used with common soldering techniques. They can also be produced in accordance with (RoHS), supporting ecologically friendly electronic solutions.
- Cost-Effective for Specific Applications: Despite having a greater starting cost than other classic PCB technologies, thick sheet ceramic PCBs are a cost-effective solution for some applications. Particularly in demanding and high-value applications, they can result in total cost savings because of the performance advantages, durability, and dependability they have