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Aluminum PCBs

Aluminum core PCBs is a metal-based, copper-clad laminate that delivers high performance, including excellent thermal conductivity and electrical insulation.

Metal core PCBs have a unique set of advantages compared to other base materials:

Less expensive. 

Aluminum is indigenous to a variety of climates, so it’s easy to mine and refine. That makes it significantly less expensive to mine and refine than other metals. By extension, the manufacturing costs associated with products using aluminum PCBs are also less expensive. Aluminum PCBs are also a less expensive alternative to heat sinks.

Friendly to the environment. 

Aluminum is a non-toxic, recyclable metal. From the manufacturer through to the end consumer, using aluminum in PBCs contributes to a healthy planet.

Better heat transfer. 

High temperatures are the cause of heavy damage to electronics. Aluminum conducts and transfers heat away from critical parts to minimize damage to the printed circuit board.

Very durable. 

Aluminum is stronger and more durable than base materials like ceramic and fiberglass. It is very sturdy, and reduces accidental breakages that can occur throughout the manufacturing process, and during handling and everyday use.

Lightweight: 

Considering its durability, aluminum is very lightweight. It adds strength and resilience to PCBs without adding additional weight.

Aluminum PCB Applications

Aluminum back PCBs are ideal for situations when thermal heat dissipation requirements very high. PCBs clad with aluminum are more effective at directing thermal energy away from printed circuit board components therefore provide better temperature management for PCB designs. Aluminum-backed designs can be as much as ten times more efficient than fiberglass-backed designs when it comes to removing thermal energy from circuit board components. The much higher thermal dissipation rate allows higher power and higher density designs to be implemented.

Aluminum-backed PCBs are used more than ever for applications of high power/high thermal heat dissipation.  Although they were originally designed for high power switching supply applications, aluminum-backed printed circuit boards have gained popularity in LED applications, including traffic lights, automotive lighting and general lighting.

Aluminum PCB Specification

The Effect of Temperature

The LED’s color, or wavelength, will change with temperature. As the die temperature increases, the wavelength of the color increases. This is particularly important with white light. The human eye can differentiate small color changes in white light. When Power LEDs are populated in an array, consistent thermal resistance from one die to the next assures consistent color. Because of the comparatively low thermal resistance Thermal Clad offers versus FR-4, die temperature is less affected by slight variances in the junction-to-case thermal resistance that occurs with eutectic or epoxy-die mounting techniques. It is also possible to pack the die more closely in an assembly that utilizes good thermal management techniques, thereby reducing the effects of temperature. Generally, a 30-50 percent drop in light output for a constant-forward current indicates end-of-life for Power LEDs. Power LED lifetimes have been extrapolated to over 50,000 hours.

Cost of Heat Summary

Better thermal management allows more forward current to be applied to the LED, which means more light and possibly reducing the number of LEDs required for the desired light output. Maintaining a cooler assembly at an equivalent power equates to more light per die.