Detailed Guide on Aluminum PCB
Aluminum PCB
Aluminum PCB is a type of Printed Circuit Board (PCB) having conductive dielectric material with a thin layer, laminated between a metal base and a copper foil. Developed in the year 1970, the usage of that metal became common, and a dramatic increase in the applications took place.
The other products are Aluminum Clad, Aluminum Base, Metal Clad Printed Circuit Board, Insulated Metal Substrate, and many others. However, there would be no performance difference in these products. It has a similar layout as other PCBs. The layer present in that PCB is copper, solder mask, and silkscreen. You can get the PCB with single and double sides.
What are the advantages of Aluminum PCB?
The Aluminum PCB is the solution provider for high power and tight tolerance apps and offers users some of the following advantages.
- Cost-Effective: You can get the Aluminum metal in different varieties of climates; hence it would not take time to mine and refine them. You can get them manufactured at lower costs compared to other metals.
- Environment-friendly: The other advantage you get in Aluminum is that you won’t find it toxic while using. Even when you manufacture the PCB with Aluminum, it would be conducive for conserving energy as it has a simple assembling. Also, you can recycle the metal. Also, it helps the PCB suppliers to maintain the planet’s health.
- Heat dissipation: Electronic items have a risk of getting damaged when the temperature becomes high. Hence, you need to use a material that can transfer heat. Aluminum can dissipate heat away from vital components. Hence, it is the area in which Aluminum holds the upper hand over other metals.
- More excellent durability: Among all the metals, Aluminum is the strongest & the most durable material that would reduce the accidental breakage at the time of manufacturing & handling.
- Lightweight: Aluminum is not only durable, but it is also a lightweight metal. It has a unique combination of adding strength & resilience without any weight addition.
Aluminum PCB’s Structure
Aluminum PCB comprises CCL materials, having similar features to FR4 PCBs. Its basic structure has four layers.
- Copper Foil Layer: It is a thicker layer, unlike the normal CCL, with more capacity to carry a larger current. The Copper Foil Layer forms a printed circuit used for releasing the device’s assembly and connection. Though FR-4 has the thickness and the line width equal to the Aluminum substrate, the latter can carry more current.
- Dielectric Layer: It is a thermally conductive layer in a PCB having a thickness of around 50µm to 200µm. The low thermal of a Dielectric Layer makes it suitable for its application.
- Aluminum Base: Made up of Aluminum substrate, the Aluminum Base is the third layer having a high thermal conductivity.
- Aluminum Base Membrane Layer: It is a selective metal that protects the Aluminum surface safe from scrapping & unwanted etching. The types of Aluminum Base Membrane Layer vary from 120 to around 250 degrees.
- Insulating Layer: It is the Aluminum substrate’s core technology that bonds and insulates the heat conduction. Among all the thermal barriers, the Aluminum substrate is the most significant thermal barrier in the power module structure. The quality of the thermal conductivity in an insulating layer plays a vital role in spreading the heat generated while operating the device. If the device has a low operating temperature, the module’s power load, longevity, and power output will increase while the volume gets reduced.
- Metal Substrate: The insulation of the Metal Substrate would depend on the kind of metal that you consider for expanding thermals, coefficient, conductivity, and many others. If the cost, condition, and technical performance are your concern, then an Aluminum plate would be more efficient than other metal substrates.
You can get the Aluminum plates in various sizes in which 6061, 5052, 1060 are among those plates. Do you have a higher requirement for thermal conductivity, mechanical properties, electrical, or any other property? Then, you can opt for the plates like copper, stainless steel, iron, and silicon plates.
What are the applications of Aluminum PCB?
The PCB made of an Aluminum base has a reputation for thermal dissipation function, which you can incorporate in the areas like:
- Audio equipment: You can find Aluminum in audio devices like I/O amplifiers, balanced amplifiers, audio amplifiers, and many others.
- Power Supply equipment: The manufacturers utilize Aluminum to make stabilizers, conditioners, DC-AC adapters, and others.
- Communication electronic devices: The high-frequency amplifiers and filter electrical circuits come under the Communication electronic device.
- Computers: The Computer accessories are prone to get heated after a few hours, for which the manufacturers would insulate Aluminum for dissipating heat.
- Power modules: The aluminum work in power generators like inverters, voltage regulator, automatic safety control system, and lightning conversion system.
- Electronic control: Relays, Bases of transistors, and other various circuit components would use Aluminum for effective functioning.
- Lamps & Lightning: It would support promoting the products like energy-saving lamps and LED lights that come on the market.
Aluminum PCB’s storage condition
It would be advisable to store the PCBs made of Aluminum in a dark and dry environment. Most PCBs with Aluminum-make are sensitive to moisture, yellowing, and blackening. You would require using them within two days or 48 hours immediately after opening the vacuum package.
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