——High-Efficiency Design Solving Thermal Challenges in RF Applications
1. Customer Challenge
- Application: 5G Base Station/Radar Power Amplifier
- Pain Points:
- Low Efficiency: Only 35% at 6GHz, causing excessive heat
- Unstable Performance: Return loss > -15dB, signal reflection issues
- Material Limitations: FR4-only PCB led to dielectric loss (Df > 0.02 @10GHz)
2. KKPCB Breakthrough Solution
（1）Hybrid Material Stackup
- Rogers RO4350B (top/bottom) + FR4 (core):
- Df < 0.0037 @10GHz, reducing insertion loss by 40%
- CTE-matched to prevent delamination
（2）Coplanar Waveguide (CPW) Optimization
- 3D EM Simulation (HFSS): Optimized trace width/gap to achieve:
- Return loss < -20dB across 6GHz bandwidth
- Impedance tolerance ±5% (vs. industry ±15%)
（3）Thermal Management
- Embedded Copper Plugs: Under power transistors, reducing thermal resistance to 1.2°C/W
- Via-in-Pad + Thermal Pads: Lowered hotspot temps by 22°C at 30W output
3. Measured Results
| Parameter | Original | KKPCB Solution | Improvement |
|---|---|---|---|
| Efficiency | 35% | 52% | +48% |
| Return Loss | -12dB | <-20dB | 66% better |
| Output Power | 25W | 30W stable | +20% |
| Yield Rate | 85% | 98.3% | Costs ↓13% |
▸ Enabled client to pass 3GPP 5G NR RF tests
▸ Ramp-up to 10K+ monthly production within 3 months
4. KKPCB RF Expertise
✅ Hybrid RF Materials: Rogers/Taconic/FR4 combinations
✅ Millimeter-Wave Ready: Supports up to 77GHz (5G mmWave/ADAS)
✅ High-Power Design: Certified for IPC-2152 current-carrying standards
► Need a High-Efficiency RF PCB?
Contact KKPCB for free impedance modeling & thermal analysis:
? Email:sales@kkpcb.com
