Aluminum Base PCB Manufacturer

Description

Aluminum base PCB manufacturer

As a professional and reliable supplier with more than ten years of expertise in the manufacturing of  Aluminum printed circuit boards, FX PCB can manufacture single-layer Alu PCB and 2 Layer / double sided Aluminum PCB. We are able to supply you with small, medium, or mass production at a reasonable cost on Aluminum PCB, and quality is always the key essential for us FX PCB passed the ISO9001 and the manufacturing process will strictly follow the quality control.

Aluminum PCB Stackup

The aluminum PCB substrate is a metal-based copper-clad laminate with a good heat dissipation function. The single-layer Alu PCB is composed of a three-layer structure: circuit layer (copper foil), insulating layer， and metal base layer, see below stack up for your reference:

We also designed a 2 Layer Aluminum PCB and multilayer Alu PCB for the high-end usage

Aluminum Base  PCB Capability:

Items	Capability
Board Classification	Aluminum Base, Copper Base, Ceramics Base, Copper-Clad, Combined Bade Board
Material	Domestic Aluminum, Domestic copper, imported aluminum, imported copper
Surface Treatment	HASL/ENIG/OSP/Silver
Layer Count	Single-sided printed board/Double-sided printed board
Max.Board Size	1200mm*480mm
Min.Board Size	5mm*5mm
Trace width/Space	0.1mm/0.1mm
Warp and twist	<=0.5%(Thickness:1.6mm,Board Size:300mm*300mm)
Board Thickness	0.5mm-5.0mm
Copper Thickness	35um/70um/105um/140um/175um/210um
Min.punching Hole	1.0mm(Board thickness below1.0mm)
Min Hole Diameter	0.6mm
Min.Solder Mask Opening	0.35mm

Aluminium PCB Manufacturing  Process:

 

What kind of field you can use for the Alu /Aluminum PCB

1. LED: It needs to use the Aluminum PCB Led board for Different kinds of LED and Lamps

2.  Audio equipment: input and output amplifiers, balanced amplifiers, audio amplifiers, pre-amplifiers, power amplifiers, etc.

3. Power supply: Switching regulators, DC/AC converters, SW regulators, etc.

4.  Communication electronic equipment: The high-frequency amplifier `filtering appliance` transmission circuit.

5.  Automation equipment: Motor drivers, etc.

6. Automotive: Electronic regulator, igniter, power controller,

7. Computer: CPU board, floppy disk drive, power supply unit, etc.

8. Power module

9. Inverter, solid-state relay, rectifier bridge, etc

How to Keep your Aluminum Circuit Boards?

Keep your Aluminum PCB in a dry and dark place. You should use your PCBs within 48hours once you open the vacuum package

MAJOR Aluminum PCB MATERIAL SUPPLIER for FX PCB:

Supplier	Material	Origin
Boyu	Aluminum	Huizhou China
Mingrong	Aluminum	Shenzhen China
Naya Metal	Copper	Dongguan China
Shengyi	Copper Clad Laminate	Guangdong China
Taiyo	Solder Mask	Japen
Guangxin	Solder Mask	Guangzhou China

 

Definition of Aluminum PCB Board

Aluminum PCBs are one type of metal core PCBs (MCPCB), and they are quite similar to FR4 PCBs in terms of their manufacturing process or technique, including the etching of thick copper foil, the protection against aluminum surface etching, the production of aluminum boards, and the printing of solder masks, among other things.

Aluminum core PCBs are used extensively in a variety of industries, including high-power LED lighting, power, television backlight sources, automotive, computers, air conditioner variable-frequency modules, aerospace electronics, telecommunications, medical care, audio, etc. due to their excellent electrical performance, thermal dissipation capability, electromagnetic shielding, high dielectric strength, and bending resistance.

Even when it comes to the most widely used cell phone camera, aluminum PCB is a crucial component of the phone.

A Little Background and Development of Aluminum PCB Board

Aluminum PCBs were created in the 1970s, and after being used for the first time in power amplification hybrid ICs, they became widely used (Integrated Circuits). Due in large part to the LED industry’s inspiration, aluminum PCBs have recently seen an expansion in their use and development trend.

Therefore, in order to properly utilize aluminum PCBs in your products or industries, it’s crucial to be aware of several key properties of these components.

I’ll reveal more information about the Introduction to Aluminum PCB in this article. It is a form of PCB in which the copper layer and aluminum metal are separated by a dielectric substance that is thermally conductive and electrically insulating.

It is a kind of PCB where the copper layer and aluminum metal are separated by a dielectric substance that is thermally conductive and electrically insulating. For applications requiring high temperatures or heat dissipation, this PCB is a very good option.

Let’s investigate Aluminum PCB in more detail.

 What are its benefits over conventional PCBs, as well as its primary uses?

Before investigating aluminum PCBs, it is important to understand what a PCB is. The term “PCB” stands for “printed circuit board,” which is a single board with integrated conductive channels and traces used to electrically link various electronic components. A conductive route is created using copper and is bonded onto the substrate material.

• The copper foil adopts the desired circuit pattern, while the aluminum base permits heat-dissipating with the aid of a dielectric placed between the layers.
• Aluminum PCB, also known as metal base PCB, is a type of PCB that consists of copper-clad laminate and a thin dielectric thermally conductive and electrically insulating layer of aluminum.

Constructions made of aluminum often have three layers.

1. Circuit Layer: This copper layer ranges in thickness from one to ten ounces.
2. Insulating Layer: A dielectric layer made of a substance that is both electrically and thermally conducting.
3. Base Aluminum Layer: This layer is mostly made of a metal substrate made of copper or aluminum. Although there are several thicknesses available, 1mm is the most popular thickness.

What Are the Types of Aluminum PCB?

Based on their structure and design, many types of aluminum PCBs are employed in a wide range of applications.

However, the primary function of all aluminum PCBs is essentially the same—to provide heat dissipation solutions for high-temperature applications. The primary categories of aluminum PCBs are shown below.

Flexible Aluminum PCB

Flexible dielectric is a new addition to the development of aluminum products.  It consists of polyimide resin combined with ceramic filters that exhibit high flexibility, thermal efficiency, and excellent electrical insulation.

When these materials are applied to aluminum, the resultant product does not require expensive cables or connectors because of its flexibility.  Like ordinary flexible PCBs, once they take on a certain shape, they cannot be changed or modified.

Hybrid Aluminum PCB

• In hybrid aluminum construction, thermal materials with an aluminum foundation are added after non-thermal components have been processed and refined individually.
• The most typical approach is creating structures with 2 or 4 layers, which are often made of FR4 material.
• The aluminum base, which provides stiffness, aids in the dissipation of heat and is a non-thermal material that is bonded with thermal material is favored over utilizing only thermal materials since it is less expensive and has better thermal conductivity than standard FR4 products.
• The development of this product does not necessitate the use of heat sinks or assembly procedures.
• The aluminum base’s component windows make it simple to change through-hole components.
• This enables the movement of cables and connectors across the substrate. Additionally, the solder fillet’s seal removes the need for pricey adapters.

Multilayer Aluminum Base PCB

• Power supply products frequently use multilayer aluminum PCBs, which have numerous layers of thermally conductive dielectric.
• These materials work best when paired with one or more layers of circuitry in which blind vias that also serve as a signal or thermal vias are used to bury thermally conductive dielectric between the layers.
• These designs’ single-layer architecture is ineffective, but when they feature more complicated patterns, they offer the perfect solution for many applications needing heat dissipation.

Through-Hole Aluminum PCB

• A single layer of aluminum is back-filled and pre-drilled before applying lamination, forming a Core of multilayer constructions, which pertains to the most complex constructions.
• The thermal materials are then laminated onto both sides of the metal using thermal bonding materials.
• After lamination, the assembly is subjected to drilling.
• The plated-through holes produced by drilling must pass through aluminum clearances in order to preserve good electrical insulation.

What Are the Properties of Aluminum Base PCBs?

1. Aluminum PCB Construction

It authentically refers to the aluminum copper-clad laminate (CCL) construction for aluminum PCBs, which consists of copper foil, a dielectric layer, and an aluminum base membrane (selective).

2. The layer of Copper Foil

Similar to regular CCLs, aluminum CCLs have a copper foil layer and a significant current-carrying capacity needed by the circuit layer. This is the reason why copper circuits that range in thickness from 1oz to 10oz are chosen. To increase peel-off strength, copper foil must undergo chemical oxidation treatment on the reverse side while the surface side must undergo zincing and brass plating.

3. Dielectric Layer

The main component of aluminum CCL’s dielectric layer is a layer of thermally conductive dielectric material with a low thermal resistance that ranges in thickness from 50 m to 200 m. It has great anti-thermal aging performance and can bear both mechanical and thermal stress.

4. Base Layer of Aluminum

The supporting element of an aluminum base layer is aluminum substrate material. High heat conductivity is required, as well as suitability for standard mechanical production processes including drilling, punching, and cutting.

5. Aluminum Base Membrane

The aluminum base membrane aids in preventing agent etching and scraping of the metal surface. Membranes can be divided into two categories: ordinary (less than 120°C) and anti-high temperature (more than 250°C). The latter type satisfies the HASL (hot air solder leveling) specification for surface finish.

Aluminum PCB: performance

Aluminum PCBs perform better in terms of thermal dissipation than standard FR4 PCBs and can remove heat more quickly. Consider comparing FR4 PCB with aluminum PCB with an equivalent 1.5mm thickness. In comparison to aluminum PCB, the thermal resistance of FR4 PCB ranges from 20°C/W to 22°C/W. Aluminum can therefore effectively dissipate heat.

1. Thermal Expansion

All substances experience heat expansion and contraction, and the thermal expansion coefficients of various substances vary. Due to aluminum PCBs’ outstanding thermal dissipation capabilities, problems with component thermal expansion and contraction on board surfaces can now be significantly reduced, improving the lifespan and dependability of entire appliances and electronic devices.

This benefit of aluminum PCBs, in particular, works well for SMT thermal expansion and contraction problems (surface mount technology).

2. Dimensional Stability

PCBs made of aluminum have a size that is obviously stable. Only 2.5% to 3.0% of their size changes when they are heated from 30°C to 140°C or 150°C.

Other Performances

• Effective in controlling the thermal expansion of circuit design;

• Suitable for power device SMT;
  • Helpful in lowering the working temperature, enhancing the power density and dependability of the product, and extending the product’s shelf life.
  • A reduction in the size of the product and the price of the hardware and assembly.
  • Replacing the delicate ceramic foundation with one that has superior mechanical endurance and insulating properties.

Aluminum base PCB: classification

Aluminum PCBs can be divided into three groups based on the type of application and the substance of the dielectric layer:

• Universal Aluminum PCB – Epoxy glass fiber prepreg is used to create the dielectric layer.
• Aluminum PCB with High Thermal Conductivity – The dielectric layer is made of epoxy resin or another type of resin with a high thermal conductivity.
• High-Frequency and Microwave Aluminum PCB – Polyolefin resin or polyimide resin glass fiber prepreg is used to create the dielectric layer.

What Materials Are Utilized for Aluminum PCB Insulation?

Hard or rigid and soft or flexible circuits can both be found on an aluminum printed circuit board. The copper circuit layer does not bury on the outside or inside.

The fundamental elements of a typical aluminum PCB are:

• Aluminum foil,
• prepreg,
• laminate,
• layers of the solder resist

It is a thin glass fabric called prepreg. The mechanical substrate that the resin is held in place on is glass. The prepreg enters the oven part of the machine and dries there.

The resin weakens and melts as the prepreg is exposed to higher temperatures (usually above 300 degrees F). We employ prepreg sheets to adhere PCBs to one another. Additionally, they are employed in the construction of the laminate, the PCB’s second component.

The laminate, often known as an aluminum-clad laminate, is made up of a prepreg sheet. Aluminum foil sheets can be placed on either side, and it can be bonded together under pressure and heat.

Aluminum PCB Manufacturing Challenges and Solutions

Regarding the production of FR4 PCBs, single-layer, double-layer, and multi-layer aluminum PCBs—also known as MCPCBs—have a lot in common. Aluminum PCBs, a class of sophisticated PCBs, nonetheless have unique production requirements that necessitate strict and efficient management and control.

Thick Copper Foil Etching

Copper foil is relatively thick because aluminum PCBs are frequently used in power devices with high power densities. Copper foil etching needs trace width adjustment when it is 3 oz thick or more. Otherwise, after etching, the trace width will not be within tolerance.

The subsequent work must therefore be completed in advance to ensure ideal trace width/spacing and impedance management that can satisfy design requirements.

1. A proper design should be made for trace width compensation.
2. Trace manufacturing’s impact on trace width/spacing ought to be eliminated.
3. Agent parameters and etching factors need to be tightly regulated.

• Solder Mask Printing

Due to the impact of thick copper foil, solder mask printing is regarded as a manufacturing challenge when fabricating aluminum PCBs. A significant discrepancy will be created between the trace surface and the baseboard if the trace copper thickness is unusual after image etching, making the solder mask challenging to apply. The following guidelines ought to be followed to achieve flawless solder mask printing:

1. Solder mask oil should be removed using superior workmanship.
2. The printing of solder masks twice is employed.
3. When necessary, the solder mask is applied after resin filling in the production process.

• Mechanical Manufacturing

Aluminum PCBs are mechanically manufactured using mechanical drilling, milling, molding, v-scoring, and burr-leaving on internal vias, which weakens the electrical current. Therefore, it is important to adhere to the following guidelines while manufacturing mechanical components:

1. For low-volume production, professional milling cutters and electric milling machines should be chosen.
2. When die molding, control technique and pattern should be observed.
3. On thick copper aluminum PCBs, drilling settings should be properly controlled to prevent burr generation.

 FR4 Vs Aluminum PCB

The most popular metal core PCB is one with an aluminum core. Nowadays, aluminum PCB vs fr4 is the more popular variety. What distinguishes aluminum PCB from fr4 then?

Price

A relatively conventional board material is FR-4 PCB. His cost is hence not high. Aluminum PCB cost vs. Fr4 is slightly more expensive.

Conductivity of heat

Compared to FR4, aluminum PCB offers superior thermal conductivity. Thus, aluminum PCB is preferred by producers of led lighting.

Applications

More FR-4 PCBs are used than aluminum PCBs. Because FR-4 is a conventional material that is also reasonably priced. Manufacturers prefer it as a result. The only industries that will use pricey aluminum substrates are those that demand great thermal performance.

Outstanding Benefits of Aluminum PCB

• Aluminum PCBs are a great option for applications involving high temperatures and long operating times due to the high level of heat dissipation they offer.
• Another advantage of aluminum’s effectiveness and economy is its low price. Aluminum is a widely used metal that is inexpensive to mine and process. It is also widely accessible.
• Because aluminum is non-toxic, it is safe for the environment and a great material for uses including product recycling.
• Compared to fiberglass and ceramic materials, aluminum-based products offer substantially higher levels of strength and durability.
• Compared to other metals, aluminum is a particularly strong and sturdy substance that can withstand higher strain and stress during manufacturing and material handling.
• Aluminum is quite light. It increases the product’s strength and durability without increasing weight.
• When compared to old epoxy glass, the thermal conductivity of the utilized dielectric is 5 to 10 times higher.
• Thermal transfer is more dependable and efficient than conventional PCB.

What Are Aluminum PCB Applications?

• Although these devices were primarily created for high-power switching applications, they became sufficiently well-liked when used in LED applications.
• The aluminum design maintains the temperature tolerance within predetermined limits by operating at a greater current for installed LEDs.
• The automobile and RF sectors go above and above to make these goods’ benefits accessible to the general public.
• Aluminum PCBs are a good option for applications requiring heat dissipation since they offer a perfect means for the heat to depart with the aid of dielectric, keeping the design’s overall temperature.

 

Important Factors to Consider While Choosing an Aluminum Base PCB  Manufacturer

Most of the time, the same aluminum PCB manufacturing technique is used by all aluminum base PCB manufacturers. The degree of automation of their operations, the use of cutting-edge technology, and equipment are the only substantial differences between aluminum-based PCB producers.

Circuit boards made of aluminum

Aluminum PCB makers must take into account a few crucial factors in order to effectively produce any quantity of aluminum circuit boards.

Equipment for specialized imaging

For LED applications, a lot of aluminum-backed PCBs are required, and they are significantly longer than the production panels used in conventional aluminum PCB manufacture. Manufacturers of aluminum-based PCBs are required to have screen-printing equipment or specialized UV imaging equipment that is 60 inches wide.

Equipment for Specialized Scoring

Aluminum PCBs cannot be managed using the more widely used equipment available to obtain V-scores from conventional FR-4 materials. When possible, aluminum base PCB manufacturers can assist customers in designing the most affordable array to score panels.

Testing at In-Line High Voltage

Customers want to know whether the product they are purchasing has passed a voltage test, which is a distinctive need of PCBs. Withstanding voltage testing is a part of electrical test settings, which significantly lowers the cost to the customer.

If you are looking for an Aluminum base PCB manufacturer in China, no matter whether you are looking for Aluminium PCB Prototyping or mass production, FX PCB will be glad to offer you the aluminu PCB cost for your reference, please contact us by email!