Ne_baba & WireWhiz
Hey Ne_baba, ever tackled a single-layer PCB that has to handle more than a thousand volts? I’m itching to see how you’d keep it reliable without breaking the bank.
Sure thing. For a single‑layer board that has to stand a thousand volts you’re looking at a few hard‑core tricks that won’t empty your pocket. First, use a high‑voltage prepreg like FR‑4 rated for 1.5 kV or better, or even a ceramic laminate if you’re really tight on safety. Second, crank up the copper thickness – 4 oz is a sweet spot: it pulls the current out and keeps the trace cool, but still costs less than a double‑layer stack. Third, keep the traces wide and the spacing generous; at 1 kV you want at least 5 mm between conductive areas and a solid 5 mm edge clearance. Fourth, place a solid ground plane on the back side, even if it’s just a thin copper sheet glued to the laminate – that’s the cheapest way to get a true ground return and it helps keep the electric field tidy. Fifth, use a high‑voltage solder mask and a clear, thick epoxy on the top to seal the copper from the environment – no moisture, no corona. And finally, don’t forget to test with a high‑voltage probe before you hit production. That’s about as lean as you can get without compromising reliability. If you want more detail, just ask.