What is the Aluminum PCB
Aluminum PCB is a metal based copper clad plate with good heat dissipation function. Generally, a single panel consists of three layers of structure, namely, a circuit layer (copper foil), an insulation layer, and a metal substrate. Common in LED lighting products. There are two sides, the white side is used to weld LED pins, and the other side is aluminum in natural color. Generally, it comes into contact with the heat conductive part after being coated with heat conductive paste. Currently, there are also ceramic substrates, etc.
LED Aluminum PCB is a PCB, which also means printed circuit board. However, the material of the circuit board is aluminum alloy. Previously, our common circuit board material was glass fiber. However, due to the large heat generated by LEDs, the circuit board used for LED lamps is generally Aluminum PCB, which can conduct heat quickly. Circuit boards used for other equipment or electrical appliances are still glass fiber boards!
Working principle of Aluminum PCB
The surface of power devices is mounted on the circuit layer, and the heat generated during device operation is quickly transferred to the metal substrate through the insulating layer, which then transfers the heat out, thereby achieving heat dissipation for the device.
Compared to the traditional FR-4, Aluminum PCBs can minimize thermal resistance and provide excellent thermal conductivity; Compared with thick film ceramic circuits, its mechanical properties are extremely excellent. In addition, Aluminum PCBs have the following unique advantages: meeting RoHs requirements; More suitable for SMT processes;
In the circuit design scheme, heat diffusion is treated extremely effectively, thereby reducing the operating temperature of the module, extending its service life, and improving power density and reliability; Reduce the assembly of heat sinks and other hardware (including thermal interface materials), reduce product volume, and reduce hardware and assembly costs; Optimizing the combination of power circuits and control circuits; Replace fragile ceramic substrates for better mechanical durability.
Structural composition of Aluminum PCB
- Line layer
The circuit layer (typically using electrolytic copper foil) is etched to form a printed circuit for assembly and connection of devices. Compared to traditional FR-4, Aluminum PCBs can carry higher currents with the same thickness and line width.
- Insulating layer
Insulating layer is the core technology of Aluminum PCB, mainly playing the functions of bonding, insulation, and heat conduction. The Aluminum PCB insulation layer is the largest thermal barrier in the power module structure. The better the thermal conductivity of the insulation layer, the more conducive it is to the diffusion of heat generated during device operation, and the more conducive it is to reducing the operating temperature of the device, thereby achieving the goals of increasing the power load of the module, reducing the volume, extending the life span, and improving power output.
- Metal base
The metal used for insulating metal substrates depends on comprehensive consideration of the thermal expansion coefficient, thermal conductivity, strength, hardness, weight, surface condition, and cost of the metal substrate.
Generally speaking, considering cost and technical performance, aluminum plate is an ideal choice. Available aluminum plates include 606150521060, etc. Copper plate, stainless steel plate, iron plate, and silicon steel plate can also be used if there are requirements for higher thermal conductivity, mechanical properties, electrical properties, and other special properties.
Advantages of Aluminum PCB
- Lightweight
Is one of the biggest advantages of these PCBs. Aluminum is an extremely light metal. Therefore, it helps to increase the strength and elasticity of the PCB.
- Able to dissipate heat
Important components on a circuit board can be damaged as long as they are exposed to high temperatures. Therefore, in order to protect them from such damage, it is necessary to use materials that can emit heat. Aluminum is a material that can take the heat generated away from important components on the board, thereby protecting them from any potential damage.
- Durable
Aluminum is a strong and durable material with high durability. The use of aluminum circuit boards can eliminate the risk of accidental breakage during processing, manufacturing, or daily use. Compared to glass fiber and ceramic substrates, it can provide better strength for products.
- Environmental protection
Aluminum PCBs are easy to assemble, helping to save energy. In addition, the material is recyclable and non-toxic. This makes it environmentally friendly, thereby helping to protect our planet.
- Economy
Aluminum can be found in almost any climatic condition, making mining and refining easier. This helps reduce costs. Therefore, the manufacturing process involving aluminum is cheaper than other metals.
Disadvantages of Aluminum PCB
- High cost: Compared to other affordable products, the price of Aluminum PCBaccounts for more than 30% of the product price, which is not quite up to standard.
- Currently, the mainstream can only make single panel, but the process of making double panel is difficult. Currently, the domestic industry is relatively skilled in making single panel, while the process and technology of multi-layer panel are relatively mature abroad, and more people come to understand.
- Finished products are prone to problems in terms of electrical strength and withstand voltage: this problem is mainly related to the material itself.
- The aluminum base will have an impact on the pressure resistance index of the plate that does not meet the standard; The values of the entire lamp withstand voltage and the Aluminum PCBwithstand voltage are not up to standard; The impact of circuit design and structural design on withstand voltage, while the measured withstand voltage of some Aluminum PCBs used in LED lamps on the market cannot exceed 800V. So the Aluminum PCBis not very good
- Due to the mismatch between the thermal conductivity test method and the test results, there is a certain difference between the thermal conductivity of the dielectric layer and the thermal conductivity of the finished Aluminum PCB.
Application of aluminum PCB
Aluminum PCBs are suitable for applications with high heat dissipation, mechanical strength, and durability requirements. The metal core PCB effectively transfers heat and manages the temperature of the circuit. Compared to glass fiber PCBs, aluminum PCBs have a thermal emission efficiency close to 10 times. This feature enables designers to optimize the overall housing size and design of various products.
Some applications of aluminum PCB will be mentioned below
Power Supply
The power supply and regulation circuits include power electronic devices that have a higher and better heat dissipation rate than usual.
Solid-state relay
Solid state relays handle high power, and aluminum PCBs are more suitable due to their high heat dissipation.
Automobile
Aluminum PCBs are widely used in the automotive industry. Circuits installed in automotive products operate under harsh atmospheric conditions and require lightweight and durable strength.
LED light
Aluminum printed circuit boards are widely used for LED lamp boards. LEDs are sensitive components, but they generate excessive heat. If this heat is not regulated, their performance can be severely affected and lead to premature expiration.
In addition, aluminum PCB is a good reflector that can save the cost of reflectors in low-level lightning products.
How to select an aluminum PCB manufacturer?
When selecting a brand for your custom aluminum PCB manufacturer, always consider some key factors.
Automated Manufacturing Plant
The aluminum PCB design process is limited and requires special attention. Advanced automated manufacturing units produce high-quality PCBs. Your MCPCB manufacturer’s laboratory must be equipped with modern automated machines.
Anvestment portfolio
Inexperienced aluminum PCB manufacturers may not be able to develop standardized PCBs. Experienced manufacturers adapt to change and innovation over time. Before placing an order, it is important to consider your manufacturer’s product portfolio.
Authentication
Your PCB must meet the specified quality standards. Non certified manufacturers do not meet these standards and provide unreliable products.
Graded material
The unique design and materials of aluminum PCBs are very useful for achieving higher heat emissions. Using high-quality materials can achieve higher quality. The use of deteriorated aluminum alloys or other materials can damage the reliability and durability of PCBs.
Lead Time
If you need to design, develop, and deliver PCBs within a limited time, you must consider the lead time when selecting a manufacturer. Some manufacturers require longer time than usual.
Minimum order quantity
Each manufacturer accepts orders with a minimum unit limit. If you are looking for a limited unit of development, you should consider the minimum order quantity provided by the manufacturer.
summary
As a substrate material in the production and manufacturing of PCB Aluminum PCBs, metal aluminum based copper clad plates mainly serve as connection, insulation, and support functions for PCB Aluminum PCBs, and have significant interference with the transmission speed, energy loss, and characteristic impedance of signals in the circuit. The performance, quality, processability in production, manufacturing level, manufacturing cost, and long-term reliability and stability of PCB Aluminum PCBs are largely dependent on metal aluminum based copper clad panels. Aluminum based PCBs have been widely used in daily life and are an important component of many electronic products.
