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Buy High Thermal Conductivity Aluminum PCB - Top China Suppliers & Factory for Quality Circuit Boards Companies, Factory
Product Description
What is Aluminum PCB?
| Structural layer | Common materials | Core function |
|---|---|---|
| Circuit layer | Electrolytic copper foil ranging from 18 to 140μm | Make circuits and carry the welding of components |
| Insulating layer | Thermal conductive epoxy resin/ceramic filling adhesive | Insulation isolation + heat conduction (thermal conductivity 0.8-8W/m · K) |
| Metal base layer | Aluminum alloy (mainly 6061/5052) | The heat dissipation base quickly disperses the heat conducted by the insulation layer |
Main Application Scenarios
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LED Lighting
LED beads (especially high-power LEDs) generate concentrated heat. Aluminum substrates are the core substrates for street lamps, spotlights, and panel lights, keeping temperature rise within a safe range.
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Power Electronics
Power modules (MOSFETs, IGBTs) of power adapters, frequency converters, and inverters need to dissipate heat quickly to prevent component burnout.
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Automotive Electronics
On-board LED headlights, power controllers in the engine compartment, motor driver boards for new energy vehicles.
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Audio Equipment
Power amplifier boards, audio power modules — reducing sound quality distortion caused by heat generation.
Core Features
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🌡️Ultra-High Heat Dissipation The metallic thermal conductivity of aluminum plates quickly transfers heat generated by components (such as LEDs, power transistors) to the external heat dissipation structure, significantly reducing temperature rise and extending service life.
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⚖️Lightweight + High Mechanical Strength The density of aluminum alloy is much lower than copper and steel. Its bending resistance and impact resistance are superior to ordinary PCBs, making it suitable for portable and vehicle-mounted devices.
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📐Good Dimensional Stability The coefficient of thermal expansion (CTE) of aluminum alloy can be matched with components, reducing warping and solder joint cracking caused by temperature changes.
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🛡️Insulation Safety The insulation layer can withstand high voltage (common withstand voltage ≥3000V AC), preventing short circuits between the circuit and the aluminum plate.
Key Design and Manufacturing Points
Design Considerations
Heat dissipation pads: Under the pads of high-power devices, "heat-conducting pads" should be designed and connected to the aluminum plate through metallized vias (≥0.3mm).
Line width & current: The line width should be designed according to "1A current corresponding to 0.3mm line width (copper thickness 35μm)" to avoid heat generation.
Edge treatment: Burrs on aluminum plate edges can puncture the insulation layer — chamfering (≥0.5mm) treatment is required.
Manufacturing Process
Insulation layer bonding: High-temperature and high-pressure (180℃/3MPa) bonding is required to ensure the insulation layer is free of bubbles and peel strength is ≥1.0N/mm.
Surface treatment: Tin plating/nickel-gold plating is preferred; OSP (organic film has poor heat resistance) should be avoided.
Forming method: CNC milling is adopted (instead of die-cutting for ordinary PCBs) to ensure the flatness of aluminum plate edges.
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Frequently Asked Questions
❓ What is the main difference between aluminum PCB and standard FR4 PCB?
Aluminum PCBs use a metal aluminum base layer instead of fiberglass (FR4), which provides significantly superior heat dissipation. This makes them ideal for high-power applications like LED lighting and power electronics where thermal management is critical.
❓ What thermal conductivity range does the insulating layer of an aluminum PCB offer?
The insulating layer — typically made of thermal conductive epoxy resin or ceramic filling adhesive — offers a thermal conductivity range of 0.8 to 8 W/m·K, allowing efficient heat transfer from the circuit layer to the aluminum base.
❓ Which aluminum alloys are most commonly used for aluminum PCBs?
The most commonly used aluminum alloys are 6061 and 5052. These alloys offer an excellent balance of thermal conductivity, mechanical strength, and machinability suitable for PCB manufacturing.
❓ What surface treatment options are recommended for aluminum PCBs?
Tin plating and nickel-gold plating are the preferred surface treatment options for aluminum PCBs. OSP (Organic Solderability Preservative) should be avoided as it has poor heat resistance and is not suitable for the high-temperature environments these boards typically operate in.
❓ What voltage can the insulation layer of an aluminum PCB withstand?
The insulation layer of a standard aluminum PCB can withstand high voltages of ≥3000V AC, providing reliable electrical isolation between the circuit traces and the aluminum base to ensure safe operation.
❓ Why is CNC milling used instead of die-cutting for aluminum PCB forming?
CNC milling is preferred because it ensures precise, clean edges and maintains the flatness of the aluminum plate. Die-cutting, which is common for standard PCBs, can cause burrs and edge irregularities on aluminum that may puncture the insulation layer and compromise board integrity.
