When it comes to manufacturing prototype electronic circuits, aka, Dot PCB, the use of perfboard is widespread. The perfboard is a thin material shaped in small grids across the sheet. The grids have tiny holes often circled by copper.
However, if you want to make bare boards, you will want to manufacture the perfboard without coppers. Hence, we have researched on the topic and taken valuable comments of our PCB engineers to come up with the guideline on how to use perfboard without copper.
We have included the flux soldering and detailed step by step guidelines on the perfboard application without any copper.
So, aren’t you excited?
How to Use Perfboard Without Copper
Perfboards without copper clad is beneficial in many electronics and communicative sectors. However, sometimes you need to use perfboards without copper. In this case, you may want to use the aluminum clads.
Also, the flux soldering procedure is sometimes challenging, especially with the soldering of the small holes for components. However, the following steps will make the process lot easier.
You will need:
- A medium-sized plastic lid
- Aluminum foil with a size of 36 gauges
- Scriber or PCB pointer assisting tool
- Finest flux for soldering
- Piece of perfboard
- Soldering iron with a clean and fine tip
- Leather punch with rotatory feature
Once you have collected all the instruments, we can proceed to the steps. Luckily, you will get all the equipment at home and that isn’t available at home should be easily gettable from hardware shops.
Step 1: Preparing the plastic backing and aluminum foil
At first, you will need to cut the plastic lid in 2” sizes to prepare the backing for the leather punch. You can ardently use a pair of scissors to cut the plastic lid with ease.
On the aluminum foil, you will find patine or oxidized coating on the foil. Find a piece of fine steel wool to scuff off the coating carefully. Once the upper layer is removed successfully, you can proceed to the next big step.
Step 2: Punch the aluminum pad
You may want to work with larger pads instead of the smaller pads since working with the smaller pad is practically very tough. To find the right size on the punching tool, keep rotating the punch head to meet the correct size.
Once you find the right size, quickly squeeze the punching tool to meet the anvil in perpendicular motion. After that, briefly relieve the squeeze and slide in the aluminum-clad in the punching tool. Also, insert the plastic lid in the punching tool.
Now, squeeze the punching head firmly in a 90° angle and make holes through the aluminum foil. Repeat the punching process twice to make sure that it has gone through the board holes perfectly.
Step 3: Wiring the aluminum foil pad
Once you have cut holes on the foil, please don’t remove it from the punching machine. Instead, slide in the wire directly through the hole of the foil pad. After that, slowly remove the wired place from the punching machine.
You may use tweezers to remove the aluminum foil.
Step 4: Placing the punched foil pad on the contact
Now you will require placing the punched foil pad on the perfboard correctly. For this, get hold of the perforated aluminum foil using the PCB assist tool. Then using the device, slowly and surely center the punched pad right on the perfboard.
Then stab the pad on the board. Then use the tweezers to transfer the skewered pad from the perfbaord and replace it on the contact pins. You need to be careful while accomplishing the entire process.
Lastly, press the pointed tool down on the pad and help it sit at ease on the cushion.
Step 5: Soldering the pad and perfbaord
In this ardent step, we will discuss how to solder with flux for perfect contact of all the elements. However, before you begin the soldering process, we suggest you wear protective gear such as gloves and goggles. Also, make sure the soldering space has proper ventilation.
Now touch the soldering iron on the punched holed pad with a steady and firm hand. Then, dedicatedly add the flux-cored solder on the pad and make contact for 1 to 2 seconds only. You will smoothly perform the solder and flux in one go.
Sometimes the flux may not be correctly performed, and while removing the soldering iron, the aluminum foil may come off from the board. If you find any improper displacement of the foiled pad from the perfbaord, give a second touch to it using the soldering iron.
You will need to repeat the flux soldering process for all the contacts.
Step 6: Complete the project
Once you have successfully soldered each of the aluminum foils in the perfboard pad, make sure the soldering is done correctly. You can use multiple pads on the board and use it in different applications.
After you have made the pads properly, you should plan the wiring properly. Also, you may draw the wiring outline on the perfbaord ahead of the soldering process. Finally, you can use the Kynar wire to set up the entire wiring procedure.
To set up the wiring correctly, make sure you have measured the wire perfectly. Then, use a punching machine or scissors to cut the wire in the right-sized. Once cut adequately, you can set up the wiring and use the perfboard for your desired application.
So, this is our in-depth guideline on how to use perfbaord without copper pad. Thankfully, the procedure is relatively easy and straightforward. So, we sincerely aspire that you won’t find any difficulties performing the bare board manufacturing process.
Last but not least, when you use the perfboard without copper, make sure the flux soldering is completed correctly so that the contact points are secured and won’t damage at ease. It will ensure a long-lasting service under all circumstances for all types of devices.