——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: [email protected]
🌐 Web: https://www.kkpcb.net/