High Power carrying PCB Design

Hi,
Can anyone Suggest me design concept for PCB which carrying power upto 260W. This PCB will work for battery charger in Automobile. I'm warrying about IR Drop and other noise issues. Please suggest me good concept to manage this power on PCB. No of layers, trace width (battery voltage is upto 36V) and protection on board concept are major things I want to know. Please help.

The main thing is to ensure very wide tracks for the parts of the PCB that will carry the high current. There are some track width
calculators available via google that will help.
Some people also try tricks like fattening the tracks with solder (some schools of thought suggest not to rely on this because you
can't guarantee how thick the solder layer will be), or using both the top and bottom copper layer, with via holes to join them in
many places. Another way is to use fat wires as jumpers where you don't have the space for running large tracks.
This is all stuff from experience; real PCB designers may have better advice for a manufacturable design.
Also, make sure your connectors can handle it, or use soldered cables.
260W is quite manageable using the techniques listed above for the current carrying portions of the circuit.

Hi Sky_123,
thanks for your reply.

can you suggest the layer thickness for the same board of 4 layer. How much isolation height between plane layers will sufficient to avoid shortage due to heat dissipation? My design is carrying current upto 15-20 A.

I would also like to know the manage of heat dissipation through traces.

Hi,

I've never used 4-layer for anything but low power circuits. Your tracks should be thick enough that heat is definitely not
a concern. The temperature rise is a compromise with board space, but at least try to design for minimal temp rise, so that
damage due to heat dissapation is definitely not an issue, i.e. so that you don't have to consider your tracks as resistors!
i.e. your board should not be warm to the touch!

Try to keep the current carrying tracks on the outer layers.
You should use 2 ounce copper board on the outer layers.

Thanks all,
Today I got actual specification from my senior. It is not 260 W, it is 260 V. I have to design a PCB which which can carry 260 V. Please suggest me solution.

if you know the current requirement for your design , try below Trace width calculator
https://www.4pcb.com/trace-width-calculator.html
for Layer stackup, better check with your Fab shop.

You also need to watch the clearance between high voltage tracks on the same layer.
For 260V the minimum clearance between tracks is 75 thou.

try to download this tool as well, it would help you to find impedance & thermal properties of vias & tracks
https://saturnpcb.com/pcb_toolkit.htm

use maximum onze and you can add Solder mask on the trace to be easy in the heat transfer.