World Class Aluminum PCB Manufacturer in China
PCBMay is a Professional Aluminum PCB Boards Manufacturer in China,Who Provides Many Different Types Theremal Conductivities of Aluminum PCB Boards.
Every rigid and flexible printed circuit board (PCB) design is different, customized to meet the board’s purpose. The same is true for the PCB base material — fiberglass is a popular base material, but aluminum-based PCBs are also very effective in many applications. Aluminum PCBs consist of a metal-based, copper-clad laminate that delivers high performance, including excellent thermal conductivity and electrical insulation.
Many Advantages of Aluminum PCB Boards
Thermal Conductity 1.0W/mk
Thermal conductivity 1.0W/mk,ceramic filled,halogen free,MOT 130℃,there's a good bending feature from angle 30° to angle 180°.This thermal conductivty is normal.
Thermal Conductity 1.6W/mk
Thermal conductivity - 2.2W/mK, 8 times that of FR4,Tg 130℃ & Td 380℃,Excellent thermal and insulation performance,MOT 105℃,Lead-free assembly compatible.
Thermal Conductity 2.0W/mk
Thermal conductivity - 2.0W/mK, 8 times that of FR4,Tg 130℃ & Td 380℃,applications: high beam & low beam,3D lighting,power conversion,motor Drives & controllers, power supply
Thermal Conductity 2.2W/mk
Thermal conductivity - 2.2W/mK, 8 times that of FR4,Tg 130℃ & Td 380℃,Excellent thermal and insulation performance,MOT 105℃,Lead-free assembly compatible.
Thermal Conductity 3.0W/mk
Thermal conductivity -3.0W/mk,ceramic filled,halogen free,MOT 130℃,applications:LED lighting,power,conversion controllers,motor drives,rectifiers,power supply
Thermal Conductity 4.2W/mk
Thermal conductivity -3.0W/mk,ceramic filled,halogen free,MOT 130℃,Selective Preference Dielectric for Ultra Low Thermal Resistance, applications: matrix LED for auto bulb,high power LED,electric power steering
Frequently Asked Questions (FAQ) About Our Aluminum Boards Process and Capabilities
Here you will find many quick questions and answers about Aluminum PCBs,don’t hesitate to contact us,our email is email@example.com.
The most materials of Aluminum PCB are Aluminum substrate and copper clad.
We can produce the prototype of Aluminum PCB boards with quick turn 48h and one week for standard leading time,2-3 weeks for mass production of Aluminum PCBs.
The standard color of Aluminum is white. We can also provide soldermask in red, white,blue or black,also matte green,matter black,matter red or matter blue for an additional amount.
The largest size PCB we can produce is 47″ x 15″ or 1200mm x 400mm.
Yes,we can produce 2layer Aluminum PCB board.
Higher durability: Aluminum provides strength and durability to a product that ceramic or fiberglass bases cannot. Aluminum is a sturdy base material that can reduce accidental breakage during manufacturing, handling, and everyday use.
A Metal Core Printed Circuit Board (MCPCB), also known as a thermal PCB or metal backed PCB, is a type of PCB that has a metal material as its base for the heat spreader portion of the board. The thick metal (almost always aluminum or copper) is covering 1 side of the PCB.
Printed circuit boards on an Aluminum Base
Aluminum PCBs are an excellent alternative to standard PCBs when high heat dissipation is required, such as in LED luminaires. Also, boards on an aluminum base are used if the board is required to withstand strong mechanical loads and vibrations.
The high thermal conductivity provided by the aluminum base of the board allows good heat dissipation from elements such as high-power transistors or high-power ultra-bright LEDs used in LED strips and lamps.This allows you to increase the life and reduce the probability of finished product failure.At the moment, the market for LED-based lighting technology is developing at a rapid pace, and, accordingly, the demand for aluminum-based boards is growing rapidly.
Printed circuit boards on an aluminum base – used when it is necessary to remove heat and dissipate in the future. The construction of metal-based boards is very similar to conventional single-sided boards. However, the main indicator is the thermal conductivity of the material, aluminum is a very good and cheap material, which facilitates its use for removing heat from various elements that generate heat.
Aluminum base PCBs – Mainly used in lighting equipment. Since super-bright LEDs generate a lot of heat, it is necessary to dissipate it as quickly as possible in order to increase their service life and prevent overheating. There are also technologies that allow you to solder directly onto an aluminum substrate bypassing the dielectric layer.
Why are Printed Circuit Boards Made of Aluminum?
Aluminum in PCBs is used when good cooling of the device is required or to transfer heat from the components on the board to the aluminum substrate and further to the fan or more powerful heat sink. The rigidity of the structure complements the aluminum boards.
Many people think that soldering to aluminum boards is quite problematic; they come up with various nonsense about aluminum fluxes. These people just don’t understand how an aluminum PCB works.
That is, the aluminum printed circuit board on top is exactly the same as a conventional printed circuit board and the soldering of such a board occurs in the same way in furnaces with reflow profiles of lead or lead-free solder pastes. The soldering temperature depends on which paste will be applied to the board and the slightly slow speed of the oven conveyor.
It is almost impossible to heat and solder such a board manually with a hairdryer or a soldering iron, because all the heat will be instantly dissipated in aluminum. And even if you add the temperature to 500 degrees, the conductors on the board are unlikely to withstand such a heat overload.
This is the point of these boards. If powerful LEDs are soldered to them for lighting, then a large amount of heat is released, which dissipates aluminum and then this heat is transferred either to the device case or to an additional radiator. This is to extend the life of the lamps and prevent them from overheating.
Aluminum boards aren’t just used for lamps. They are used in cases where the components on the board generate a lot of heat and to prevent component failure, boards with an aluminum substrate are used.
Why Switched to Aluminum LED Boards?
New Base for LED Electronics – The aluminum LED board emerged from the need to remove a lot of heat from the LEDs.
For decades, printed circuit boards were made of fiberglass or getinax, on which a layer of metal – thin copper – was glued. Gaps between the printed conductors were etched from the layer – a printed circuit board was obtained.
The previously existing methods of heat removal from LEDs were either ineffective or technically difficult. A thin printed circuit board, for example, a powerful LED strip, was glued onto a metal substrate – a plate, strip or profile, and the heat from the LEDs went through a layer of adhesive tape, glue and heat-conducting metal and was dissipated in the environment. To increase the heat removal, fans were installed, which created noise and reduced the reliability of the device. High efficiency heat pipes were sometimes used.
How did Aluminum Boards Come About?
If an aluminum plate is anodized, i.e., a coating of aluminum oxide, which is a dielectric, is applied to the metal surface, then an extraordinary opportunity appears on the dielectric layer to place the conductive paths of the printed circuit board. This is how an aluminum analog of a printed circuit board appeared, and then one-, double-sided and even multilayer aluminum printed circuit boards with plated vias or conductive pistons.
Printed circuit boards on sheet copper are also made, but they are more expensive.
The metal layer inside the board provides good heat dissipation from the LEDs and increases the solidity of the board, especially the multilayer one.
Soldering of LEDs to an aluminum board as well as SMD-LEDs can be automated, you can solder manually.
The transition to metal boards increased the power of LED products, reliability, service life, vibration and shock resistance, and reduced dimensions.
The base of any printed circuit board is usually a dielectric or a metal base covered with a dielectric. Anodized aluminum is used as a dielectric, but sometimes copper is also used. Copper has excellent thermal conduction properties, but aluminum is the most common material for metal-base PCBs.
Aluminum Printed Circuit Board
Aluminum PCB is Optimal in Terms of Cost and Thermal Conductivity.
The simplest and most cost effective type of printed circuit board is a single sided printed circuit board with an aluminum base. A board of this type is no different from an ordinary single-layer one, only glued onto an aluminum plate. The generated heat passes through the dielectric and dissipates through the aluminum.
Recently, multilayer printed circuit boards with an aluminum base inside have been very popular. Aluminum, as elsewhere, is used as a heat sink.
We offer a wide range of printed circuit boards of various types, including flexibly rigid printed circuit boards.
With the increase in the degree of integration of the element base and the density of the placement of components on printed circuit boards, accounting for thermal processes is becoming increasingly important. The heat dissipation problem is solved by various methods. One of the main ones is the use of boards with a heat-conducting base.
Printed circuit boards with a thermally conductive base (metal base) are most often used when it is intended to use components that generate significant thermal power ( for example , high -brightness LEDs , laser emitters, etc.). The basic design of such a board includes a layer of conductors, a metal base, and a dielectric layer between them. The main properties of such a board are excellent heat dissipation and increased dielectric strength when exposed to high voltages.
Metal Based PCBs have Many Advantages over Conventional PCBs:
- Dissipate heat without using additional radiators, special heat-conducting pastes.
- Reduce / eliminate the need for forced air cooling fans.
- Add mechanical rigidity to the product.
- They increase the degree of integration of elements of high-power equipment operating with high currents and voltages at high operating temperatures.
- Reduces the effect of heat stress on all components, thereby increasing the lifespan of the elements and the durability of the product.
- The cooling properties of such boardsmake it much easier to organize heat removal, which favorably affects the cost of products.
- Due to any configuration of the circuit boards,they can significantly save space in the device.
- The boards have excellent EMC and shielding characteristics.
- The use of such cardsimproves the reliability of the devices.
PCBMAY manufactures printed circuit boards on an aluminum base for LED technology.
Boards on a metal substrate are widely used to solve heat dissipation problems in devices where, for some reason, it is difficult to install forced cooling elements or their power is insufficient for high-quality heat dissipation. In this case, the metal base is used as a radiator.
The effect of heat stress of all components is reduced, which increases the durability of the elements and the product as a whole. Due to the fact that the board can be given any shape, it becomes possible to place it in the most optimal way in the device and provide significant space savings, which is of exceptional importance with increased requirements for miniaturization of devices, for example, in aviation technology.
In addition, by using a metal for the substrate, the printed circuit boards have good EMC and shielding characteristics. The use of such boards increases the reliability of devices, mean time between failures, and resistance to mechanical stress.
Aluminum is usually used as a metal for the substrate, which allows not only to reduce the weight of the printed circuit board, but also to significantly reduce its cost.
Manufacturing of Aluminum Printed Circuit Boards(PCBs)
Almost any electronics, be it lighting fixtures,sensors and other devices,use a printed circuit board in their design.It acts as the basis on which the electric radio elements are attached and power circuits are created. To ensure high performance and durability of devices,it is necessary to take a responsible approach to the choice of consumables from which an Aluminum PCB board is created.
The reactive amphoteric metal has low thermal resistance. It allows for efficient heat removal from electrical components.This is true for equipment with high distribution and local heat loads.The metal is resistant to vibration and long-term mechanical stress.
It increases the strength and durability of the finished product. In addition, Aluminum PCB is highly resistant to repeated solution treatments (etching).It expands the possibilities for the production of complete systems.
What is an Aluminum PCB?
An Aluminum PCB is a dielectric plate,in the volume or on the surface of which electrically conductive circuits are formed. It is designed for mechanical and electrical connection of electronic components.
Printed circuit boards on an aluminum base are divided into three groups:
- One is a general-purpose aluminum-based copper clad laminate, the insulating layer is composed of epoxy glass cloth bonding sheet;
- The second is a high heat dissipation aluminum-based copper clad laminate, and the insulating layer is made of high thermal conductivity epoxy resin or other resin;
- The third is an aluminum-based copper-clad laminate for high-frequency circuits. The insulating layer is made of polyolefin resin or polyimide resin glass cloth bonding sheet.
Manufacturing an Aluminum Board on a Metal Substrate Involves Several Stages:
- Creation of a blank made of foil-clad metal;
- Additional processing to obtain the required electrical and mechanical appearance;
- Installation of electronic components;
- Testing of the finished product.
Manufacturing of printed circuit boards on an aluminum base is an excellent opportunity to buy high-quality components at reasonable prices.The main thing is to find a reliable supplier of electronic components for solving the assigned tasks.
The manufacture of Aluminum PCB is relevant for the production of various electronics and equipment. It,during operation,generate a large amount of heat or are exposed to external influences.For example, LED equipment is in great demand.
In general terms, the technological process repeats the process of manufacturing a one-sided PCB with a solder mask and hot tinning on fiberglass. But it has some peculiarities due to the difference in the physical and chemical properties of aluminum and fiberglass:
- Aluminum is a reactive amphoteric metal that reacts with both acids and alkalis.
- The high thermal conductivity of aluminum makes it necessary to change modes during hot tinning.
- The properties of aluminum differ significantly from the properties of fiberglass during mechanical processing.
The Structure of the Material is:
- A set consisting of a copper foil;
- A dielectric with low thermal resistance;
- An aluminum base.
It can significantly increase the efficiency of heat removal in products.There are increased local or distributed thermal loads.
Application of Protective Film on Aluminum PCB
Some manufacturers supply the material with a protective film on the aluminum PCB. It is quite chemically and thermally stable.It reliably protects the base during the entire processing process and can be removed after hot tinning before the second mechanical treatment.
Finishing immersion gilding is possible only with reliable insulation of aluminum.Since not only the base metal suffers in all solutions,but baths with expensive solutions are also contaminated.
Removal of the photoresist should be done in an ammonia solution (1: 3) or in proprietary solutions based on organic amines.The use of caustic alkali solutions is unacceptable,since aluminum is actively dissolved in them.
Chemical preparation before hot tinning cannot be carried out in acidic solutions of pickling and pickling due to the dissolution of aluminum and the contact release of powdered copper on it.To activate the surface,you can apply short-term etching in an ammonia solution followed by rapid rinsing and drying.
Aluminum PCB Manufacturing
Mechanical processing of aluminum PCB requires special tools and non-standard technological modes.When drilling, aluminum (as opposed to fiberglass) as a ductile metal produces continuous chips winding on the drill.
Use intermittent drilling to separate the chips or repeat the program sequentially, gradually increasing the drill penetration.The cutting edges of the tool should be well sharpened and the surfaces polished to prevent metal adhesion.
Aluminum PCB Applications:
- Audio equipment: Input&output amplifier, balanced amplifier, audio amplifier, pre-amplifier, power amplifier, etc.
2. Power supply equipment: Voltage stabilizer, regulator, DC-AC adapter, etc.
3. Communication electronic equipment: High-frequency amplifier,filter electrical transmission circuit.
4. Office automation equipment: Motor drivers, etc.
5. Computer: Power supply unit, floppy disk drive, motherboard, etc.
6. Power modules: Inverters, solid state relays, rectifier bridges, etc.
7. Electronic control: Relays, transistor bases, cooling of components in various circuits;
8. Switch, microwave: Radiator, semiconductor device insulation heat conduction, motor controller;
9. Industrial vehicles: Igniters, voltage regulators, automatic safety control systems, light conversion systems;
10. LED display (two modes: LED display; use LED light source display)
- Lamps and lanterns: With the promotion of energy-saving lamps, various energy-saving and brilliant LED lamps are popular in the market, and the aluminum substrates used in LED lamps have also begun to be applied on a large scale.
Mounting on aluminum PCB makes vias impossible.This is due to the single-layer construction.
High heat transfer rates help reduce the risk of failure of the finished device.This allows you to significantly increase the service life of products.
Aluminum is usually used as a metal for the substrate.It allows not only to reduce the weight of the printed circuit board,but also to significantly reduce its cost.
PCBs on a metal substrate are usually a three-layer structure:
- A metallization layer
- An insulating layer
- A metal substrate
The first layer is conductive.A topological pattern is applied to it,and then, by etching,all unnecessary is removed,leaving only the necessary tracks.
For the middle layer,an insulating material is used.It is certainly dielectric and has high strength.It is made from durable polymers such as polyimide.
The third layer – the bottom layer of the board – is an aluminum substrate with a thickness of 0.5 to 3 mm.The thickness of the metallized layer is chosen depending on the temperature regime and the calculated loads on the printed circuit board.To increase corrosion resistance, aluminum substrates are usually anodized.
Where to Buy Aluminum PCB Boards on Favorable Terms?
Manufacturing of aluminum pcb boards and supply of products goes through a number of complex procedures.Generally,a professional aluminum pcb manufacturer offers following advantages:
- Fast processing of incoming orders;
- Urgent production of aluminum PCBs within 3 days;
- High quality workmanship of electronic components;
- The ability to manufacture test and prototypes;
- Attractive prices.
The following table presents some of our Aluminum Core materials:
|Items||Performance Index (Measured value)|
|Peeling strength (n/mm)||1.8|
|Insulation resistance (ω)||>1*10 g|
|Breakdown voltage (vdc)||>2 k|
|Soakable soldering (°C/m)||280°C / 260°C, 1 min, no bubble & delamination|
|Thermal conductivity (ω/m-k)||>0.8|
|Thermal resistance (°C/ω)||< 1.2|
|Dielectric constant (1mhz)||4|
|Dielectric loss angle (tangent)||0.03|
Check our Aluminum core PCB manufacturing capabilities in the following table:
|Quality Grade||Standard IPC 2|
|Number of Layers||4 – 24layers|
|Order Quantity||1pc – 10000+pcs|
|Build Time||2days – 5weeks|
|Material||Aluminum core (Domestic 1060), Copper core, FR4 covering|
|Board Size||Min 6*6mm | Max 610*610mm|
|Board Thickness||0.8mm – 5.0mm|
|Copper Weight (Finished)||0.5oz – 10.0oz|
|Solder Mask Sides||As per the file|
|Solder Mask Color||Green, White, Blue, Black, Red, Yellow|
|Silkscreen Sides||As per the file|
|Silkscreen Color||White, Black, Yellow|
|Surface Finish||HASL – Hot Air Solder Leveling|
|Lead Free HASL – RoHS|
|ENIG – Electroless Nickle/Immersion Gold – RoHS|
|Min Annular Ring||4mil|
|Min Drilling Hole Diameter||6mil|
|Other Techniques||Countersink holes|
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