Embedded Heavy Copper Traces in Electric Meter PCB
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electricity consumption-measuring meters require costly heavy copper bars for current flow connectivity, which are expensive and require significant assembly and tooling changes for PCB modifications.
Innovation Solution
The use of embedded heavy copper traces within the PCB layers to carry substantial currents, reducing electrical resistance and eliminating the need for separate copper bars, with parallel traces and plated through holes for enhanced conductivity and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heavy copper bars are used for current flow connectivity, then electrical connectivity for heavy current flow is achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent merges the separate copper bar connectivity function into the PCB structure itself by embedding heavy copper traces within the PCB layers. This integration eliminates the need for separate copper bar components and their associated assembly processes, while maintaining the required heavy current flow capability through multiple parallel copper traces distributed across different PCB layers.
Solution Approach 2:
The patent embeds heavy copper traces within the internal layers of the PCB structure, nesting the current-carrying conductors inside the PCB itself. This nesting approach allows the copper traces to be contained within the PCB laminate, eliminating external copper bar components while providing robust electrical connectivity for heavy current applications.
2Reliability
If heavy copper bars are used for current flow connectivity, then heavy current flow capability is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines the heavy current carrying function with the PCB manufacturing process itself. By embedding heavy copper traces within the PCB layers during standard PCB fabrication, the design eliminates the need for separate expensive copper bar components and their specialized assembly processes, thereby reducing overall manufacturing cost while maintaining heavy current flow capability.
Solution Approach 2:
The patent replaces expensive heavy copper bar components with standard PCB manufacturing techniques using copper traces. This substitution uses more economical materials and processes that are already part of standard PCB fabrication, significantly reducing component and assembly costs while achieving the same electrical performance.
3Reliability
If separate copper bars are used for connectivity, then heavy current flow is achieved, but PCB changes require tooling changes
Solution Approach 1:
The patent merges the current carrying traces directly into the PCB layer structure, making them an integral part of the PCB design. This integration allows PCB design changes to be made through standard PCB design and manufacturing processes without requiring changes to external copper bar components or specialized tooling, thereby significantly improving PCB adaptability and flexibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces costs and simplifies manufacturing by embedding copper traces within the PCB, enabling efficient high-current flow without the need for separate copper bars, while maintaining low electrical resistance and heat management.
Implementation Method 1
The plated through holes provide electrical connection between the first and second PCB layers
Implementation Method 2
enabling efficient high-current flow without the need for separate copper bars, while maintaining low electrical resistance
Implementation Method 3
with parallel traces and plated through holes for enhanced conductivity and heat management
Data Source
AI summary
Techniques for construction of an electric meter base level printed circuit board (PCB), such as for use in an electric consumption meter, are described herein. A plurality of heavy copper traces may be embedded in the PCB, thereby eliminating the need for heavy copper bar between connectors and components on the board. In one example, a PCB includes connectors for incoming and outgoing line and neutral conductors. The PCB may include a current measuring component, mounted on the PCB, to communicate with metrology circuitry. The PCB may include one or more switches, configured to regulate electrical service. Heavy electrical traces may be embedded in the PCB to connect the connectors and various components mounted on the PCB. The heavy electrical traces are sized to allow passage of currents that may be in excess of 100 amps.