What is the Difference Between Rogers PCB and Ordinary PCB?

Material composition, performance characteristics and the applications for which both types are well suited. Rogers PCBs use specialized laminate materials manufactured by Rogers Corporation and are chosen mainly on the basis of providing high-frequency, high-performance applications. On the other hand, ordinary PCBs are made typically on FR4 materials. They are used for more general and standard electronic circuits. Several key factors must be considered including material properties, performance and the application of each PCB to understand its difference more precisely.

Material Differences

This is the most significant difference between Rogers PCB and ordinary PCB. The materials used in both of the PCB will showcase lots of differentiation among them. Some of the common materials used in both of the PCBs are given below:

Rogers PCB Materials

Rogers PCB composition consists of different varieties of high-performance laminated materials. The speciality of this material is that they are designed specifically for high-frequency applications. Rogers PCB board materials also provide excellent thermal properties. Below are some of the most commonly used materials in the Rogers PCB fabrication.

• RO3000 Series: These Rogers PCB board materials are known for their low dielectric loss, excellent thermal management and stable electrical properties. These specifications make this material suitable for use in microwave applications.
• RO4000 Series: They offer a decent balance between cost and performance. This Rogers PCB board material provides these advantages along with low dielectric constant and high thermal stability.
• RO4350B: One of the widely used Rogers laminates for RF and microwave applications. They are more commonly used for RF applications among the Rogers PCB board materials because of the low dielectric constant and low loss tangent.

Ordinary PCB Materials

In most cases, ordinary PCBs are made using FR4 material. This is a common type of substrate which is composed of woven fibreglass materials with an epoxy resin binder. FR4 is known for its low cost and acceptable performance in common applications. The dielectric constant of this material is also higher than Rogers PCB materials, which is approximately 4.5 in value. This value can cause signal degradation in higher-frequency applications. FR4 materials are very well known for their application in low to moderate frequency levels, even though they struggle to keep good signal integrity and thermal stability in more challenging environments.

Dielectric Properties

The Dielectric properties of the material used in PCBs are crucial and important. This is in particular for applications involving high frequency. Dielectric properties also affect directly the ability of the board to transmit signals with minimum loss and interference.

Rogers PCB

• Dielectric Constant: Rogers PCB board material has a low and stable dielectric constant which ranges typically from 2.2 to 3.5. If the material has a lower dielectric constant, it means that the material can support faster signal transmission with a smaller delay. This feature is critical in high-frequency and high-speed applications.
• Dissipation Factor: Rogers laminates have a lower dissipation factor. Their dissipation factor is as low as 0.002 units. This means that their dielectric constant remains stable across an inclusive temperature range. This makes them ideal for applications involving rapid thermal changes like it happens in aerospace or automotive radar systems.

Ordinary PCB (FR4)

• Dielectric Constant: FR4 has a higher dielectric constant which is typically around 4.0 to 4.5. This can cause potential signal delay and more significant signal degradation. This is applicable for FR4 materials specifically in high-speed and high-frequency applications.
• Dissipation Factor: FR4 materials have a higher dissipation factor than Rogers which often ranges from 0.02 to 0.035 units. This higher dissipation factor can lead to higher signal losses, particularly in high-frequency applications.

Cost Consideration

Cost is an important factor to be considered when manufacturing a PCB. For Rogers PCB and ordinary PCB, we can distinguish between them regarding this matter since they have different material compositions.

Rogers PCB

Rogers PCBs are generally more expensive due to their unique material composition and higher performance they offer. The cost of Rogers laminate is higher than ordinary FR4 material and also the Rogers PCB fabrication process is a bit more complex due to the laminate’s high tolerance and rougher requirement to have better signal integrity and thermal performance.

• Higher Material Cost: The superior material properties of Roger laminates like their low dielectric constant and superior thermal conductivity will make the PCB more expensive as a matter of cost.
• Dedicated Manufacturing Process: The Rogers PCB fabrication process can be more intricate because of the need for precise control over electrical and thermal properties. This will significantly add up to the overall cost.

Ordinary PCB

FR4 PCB is much more cost-friendly when compared with Rogers which makes them the go-to choices for general-purpose applications. The material cost is really low when compared with Rogers PCB and therefore the manufacturing cost of ordinary PCB will be also comparatively low.

• Lower Material Cost: FR4 is available readily in most cases and it is also very inexpensive when compared with the Rogers laminates. The inexpensive factor and quick availability make FR4 PCBs a preferred choice for consumer electronics and other cost-sensitive applications.
• Simpler Manufacturing: FR4 boards do not need the same level of precision as Rogers boards. This will lead to much lower production costs for the ordinary board.

Applications

Rogers PCB Applications

Rogers PCBs are often used in applications requiring high-frequency performance, excellent signal integrity and high thermal stability. Some of the general applications of Rogers PCB are given below.

• RF and Microwave Circuits: The use of Rogers PCB can be found in devices like mobile base stations, radar systems and satellite communications where RF and microwave signals are high in usage.
• High-Speed Digital Circuits: Rogers PCB board materials always support high-speed data transmission with minimum signal loss.
• Aerospace and Military Applications: They are utilized here because of the durability and thermal stability Rogers laminate provides for the PCB. Signal integrity is also important for PCBs since they have to work in harsh environments for military and aerospace applications.

Ordinary PCB Applications

FR4 is one of the common materials used in everyday electronics. This is mainly because of its low cost and decent performance for most of the standard applications. They are utilized in:

• Consumer Electronics: Daily use devices like smartphones, computers and household appliances rely mostly on FR4 PCB because of its simple and cheap manufacturing and production.
• Industrial Electronics: Same as for consumer electronics, industrial electronic equipment finds applications in ordinary PCB where high-frequency performance is not much required.