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'[EE]: Soldering big copper rails on PCB's'
2001\05\31@174803 by D. Schouten

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Hi all,

I am currently involved in a project that requires
a continuous DC current of 100A (200A peak) flowing
through a number of parallelled MOSFETS on a PCB.
Apart from using ultra wide traces and 105um powerboard,
I need to solder 4x12mm copper rails of 15cm long
on these traces.

I have seen this technique used in a number of power
applications in the past. But I was wondering how this
copper rail can be soldered reliably on the PCB.
Can it be done by a huge soldering iron? Or is hotair
soldering an option here?

Perhaps the rail can be soldered onto the PCB by using
solderpaste and a very big current through the copperrail
heating it up due to I^2xR losses. Although I am aware
of the huge currents involved in heating up a 48 sqrmm(!)
copperwire.

Any ideas?

Thanks!

Daniel...

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'[EE]: Soldering big copper rails on PCB's'
2001\06\01@062258 by Thomas C. Sefranek
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I have pretinned and  preheated the rails with a torch.
and then applied the hot rail to the board with a soldering iron to
"touch it up".
For the 2500 amp stuff, I ALWAYS bolt the rail to the board!

"D. Schouten" wrote:

{Quote hidden}

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2001\06\01@075023 by michael brown

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----- Original Message -----
From: "D. Schouten" <.....d.schoutenKILLspamspam.....QUICKNET.NL>
To: <EraseMEPICLISTspam_OUTspamTakeThisOuTMITVMA.MIT.EDU>
Sent: Thursday, May 31, 2001 4:47 PM
Subject: [EE]: Soldering big copper rails on PCB's


{Quote hidden}

Can you heat the copper rails in a kiln to 400C and drop them on the board
and allow to cool?

{Quote hidden}

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2001\06\01@084411 by madhu.annapragada

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I am not sure if this is an option for you as it involves a new component on
the board but I have used a CCI Rigid Bus (http://www.cci-msc.com) to carry about
60 Amps in one application. There have the added benefit of stiffening up
the board and are simple to solder. They can possibly be used in parallel to
carry more current.
Madhu
{Original Message removed}

2001\06\01@111427 by mike

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Might be worth considering induction heating of some sort - this will
be easier than using current, and the heat will be absorbed mostly
where it is needed - in the solid copper.

On Fri, 1 Jun 2001 06:45:33 -0500, you wrote:

>{Original Message removed}

2001\06\01@111701 by Dal Wheeler

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OK, you've got me curious now.  What are you doing with 2500 Amp rails on
your boards?!? 8'o
UPS's?

{Original Message removed}

2001\06\01@123733 by Thomas C. Sefranek

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Dal Wheeler wrote:

> OK, you've got me curious now.  What are you doing with 2500 Amp rails on
> your boards?!? 8'o
> UPS's?

24 Volt HIGH power PWM motor controller. (Hydraulic drive system.)

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2001\06\01@125835 by D. Schouten

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>
> Can you heat the copper rails in a kiln to 400C and drop them on the
board
> and allow to cool?
>

Yes I can. The board on which the copper rails need to be soldered
is covered with SMD components too (also underneath the location
where the rails are soldered). So to avoid the SMD parts from falling
off the board, the copper rails are soldered first and after that
the board goes into the SMD pick and place machine. This will create
an extra difficulty in order to avoid the rails from being desoldered
again during the SMD soldering stage. Although the rails are also
mounted with a big screw onto the board.

Induction heating might be an option too Mike!

Thanks sofar!

Daniel...

{Original Message removed}

2001\06\01@162907 by Peter L. Peres

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The way I usually do this is, I preheat the fluxed and tinned board with
the rails in place using either a hot air source or an oven (you can make
a temporary one by borrowing a fast food warming stand with IR lamps).
Then I solder it with a 150W iron while hot. Similar things get used for
assembling larger 'tin cans'. The food heating stand will not overcook
your board. If you use something else beware. Kitchen mitts are a must
while doing this. Be sure to keep the through holes near the reinforced
areas clear of solder. Small wooden pegs will do this. In industrial mode
they do this by using a solder with a different (higher) melting point for
the bars). The boards are equipped with bars first, then stuffed and wave
soldered. Or so I know.

Peter

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2001\06\02@114121 by Russell McMahon

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> > OK, you've got me curious now.  What are you doing with 2500 Amp rails
on
> > your boards?!? 8'o
> > UPS's?
>
> 24 Volt HIGH power PWM motor controller. (Hydraulic drive system.)



Killer Robot ? :-)

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