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OEM High Thermal Conductivity Aluminum PCB - Leading China Suppliers & Factory for Quality Printed Circuit Boards Supplier, Quotes
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
LED lighting
LED beads (especially high-power LEDs) generate concentrated heat. Aluminum substrates are the core substrates for street lamps, spotlights, and panel lights, which can keep the temperature rise of the beads within a safe range.
① Power electronics
Power modules (MOSFETs, IGBTs) of power adapters, frequency converters, and inverters need to dissipate heat quickly to prevent component burnout.
② Automotive electronics
On-board LED headlights, power controllers in the engine compartment, motor driver boards for new energy vehicles.
③ Audio equipment
Power amplifier boards, audio power modules, reducing sound quality distortion caused by heat generation.
Core features
Ultra-high heat dissipation:
The metallic thermal conductivity of aluminum plates can quickly transfer the heat generated by components (such as LEDs, power transistors) to the external heat dissipation structure, significantly reducing the temperature rise of the components and extending their service life.
Lightweight + high mechanical strength:
The density of aluminum alloy is much lower than that of copper and steel, and its bending resistance and impact resistance are superior to those of ordinary PCBs, making it suitable for portable and vehicle-mounted devices.
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.
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
The heat dissipation pads need to be fully in contact with the aluminum plate: under the pads of high-power devices, "heat-conducting pads" should be designed and connected to the side of the aluminum plate through metallized vias (≥0.3mm) to enhance heat dissipation.
Line width adaptation current: Aluminum substrates are mostly used in high-current scenarios. The line width should be designed according to "1A current corresponding to 0.3mm line width (copper thickness 35μm)" to avoid heat generation.
Avoid burrs during aluminum plate cutting: Burrs on the edges of aluminum plates can easily puncture the insulation layer, so chamfering (≥0.5mm) treatment is required.
Line width adaptation current: Aluminum substrates are mostly used in high-current scenarios. The line width should be designed according to "1A current corresponding to 0.3mm line width (copper thickness 35μm)" to avoid heat generation.
Avoid burrs during aluminum plate cutting: Burrs on the edges of aluminum plates can easily puncture the insulation layer, so chamfering (≥0.5mm) treatment is required.
Manufacturing process
Insulation layer bonding: High-temperature and high-pressure (180℃/3MPa) bonding is required to ensure that the insulation layer is free of bubbles and the peel strength is ≥1.0N/mm.
Surface treatment: Tin plating/nickel-gold plating is preferred, and 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 the aluminum plate edges.
Surface treatment: Tin plating/nickel-gold plating is preferred, and 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 the aluminum plate edges.
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Frequently Asked Questions (FAQ)
What are the structural layers of an Aluminum PCB?
An Aluminum PCB consists of three layers: a Circuit layer (electrolytic copper foil, 18 to 140μm), an Insulating layer (thermal conductive epoxy resin/ceramic filling adhesive), and a Metal base layer (aluminum alloy, mainly 6061/5052).
Why is an Aluminum PCB preferred for LED applications?
High-power LED beads generate concentrated heat during operation. Aluminum substrates serve as the core heat dissipation base, quickly dispersing heat to keep the temperature rise of the LED beads within a safe range.
What is the thermal conductivity and voltage capacity of the insulation layer?
The insulation layer has a thermal conductivity of 0.8-8W/m·K. It is designed for high safety and can withstand high voltage (withstand voltage ≥3000V AC), preventing short circuits between the circuit and the aluminum base.
How do you design the line width for high-current scenarios on an Aluminum PCB?
To avoid excessive heat generation, the line width should be designed based on the standard ratio of "1A current corresponding to 0.3mm line width" when using a copper thickness of 35μm.
What surface treatments and forming methods are recommended for manufacturing?
Tin plating or nickel-gold plating is preferred for surface treatment, while OSP should be avoided due to poor heat resistance. For forming, CNC milling is adopted instead of die-cutting to ensure the flatness of the aluminum plate edges.
