←back to thread

284 points surprisetalk | 6 comments | | HN request time: 2.051s | source | bottom
Show context
michaelt ◴[] No.42876453[source]
> Other than increased miniaturization, the most striking change is the use of copper pours [...] Why did we start doing this?

We've been doing something a lot like this for as long as I can remember.

Back in the 1990s if there were any big unused copper areas on your PCB you'd mask them to save on etching acid - a gallon of acid would have a lifetime measured in square inches of copper removed, and the less copper you removed, the longer your acid would last.

Meanwhile, a lot of DIY etching processes were very basic. Sure, you could get translucent acid and a transparent bath and heat it to a controlled temperature and run bubbles through it and so on. But if you were on a budget, some room temperature ferric chloride in an old ice cream container would get the job done. And getting the etch resist onto the board? You could draw it by hand with special pens, use transfers, there were special printer toner transfer papers, or you could DIY UV photoresist using printable projector transparencies and the sun as your UV source.

This was not a super-scientific, tightly controlled process.

If you had narrow traces and narrow gaps on one part of your PCB, and large areas of copper to remove on another? Well, if you left it in the acid long enough to remove that large area, could be the narrow traces get etched away too.

So masking off any large areas meant all the copper getting etched was about the same width - thus compensating for the poorly controlled etching process.

Of course, these days professional PCB manufacturing is orders of magnitude cheaper than it used to be. When you send your design to pcbway or jlcpcb they have much tighter control over the process, so you no longer have to worry about this stuff.

replies(2): >>42879159 #>>42881452 #
1. aylons ◴[] No.42879159[source]
Well, you may not have to worry, but if you have large unpoured areas on a design with a professional PCB manufacturer (of the traditional, high-touch kind), they will ask if you want to pour some copper there. Reason being that it makes the process faster, more consistent and reduce possible side-etching on lanes. It may not a make a difference in most cases, but you may just save some time and effort by doing this.
replies(1): >>42879245 #
2. iancmceachern ◴[] No.42879245[source]
The reason is that the copper is already there, it gets etched away. So it actually costs more to not have copper than to have it.
replies(2): >>42884818 #>>42888847 #
3. shermantanktop ◴[] No.42884818[source]
At industrial scale, surely they recover that copper from the etching fluid?
replies(1): >>42884856 #
4. andrewflnr ◴[] No.42884856{3}[source]
Even if they do, the recovery itself would surely have costs. It can't be easy.
replies(1): >>42884896 #
5. iancmceachern ◴[] No.42884896{4}[source]
Indeed, the enchant is very nasty stuff, it's not easy or clean to do so.
6. aylons ◴[] No.42888847[source]
Yes, but this costs pales in the cost of redoing in case of problems with side-etching and the overall tightened manufacturing constraints.

And yes, they get to recover the copper, at the very least to make treatment easier for discarding (copper is a very bad pollutant). But not only there's a cost, this is dealt with by waste treatment companies that will at most use the copper value to recoup some of the cost of the treatment.