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Aluminum PCB Manufacturing: A Complete Overview in 2020


A Brief Introduction to Aluminum PCB Manufacturing

Aluminum PCB manufacturing is the increasing trend in the modern Printed Circuit board industry. Their high thermal conductivity and better performance make them the first choice for electronics that require high heat dissipation.

Your choice of Printed Circuit Board would greatly impact the future of your electronics. Therefore, you need to make the right decision, the first time. Once incorporating the Printed Circuit Board, make changes would cost you greatly.

There are several types of Printed Circuit Boards out there, each type catering a certain category of electronics. We are not going to talk about a different type of PCB, on the contrary, our focus would be on a particular type of PCB- Aluminum PCB.

Aluminum Printed Circuit Board: Introduction

Aluminum PCB manufacturers generate aluminum alloy after several heat treatments and pre-drawing processes. These steps are imperative to ensure the quality of Aluminum alloy. You cannot compare its strength with either the 2XXX system or the 7XXX system.

However, manufacturers do enjoy the processing performance, electroplating characteristics, welding power, and corrosion-resistant of its silicon and magnesium alloy. Furthermore, it offers toughness, compact material, no deformation and defect-free material.

Polishing and coloring are also easy and efficient. The amazing oxidation effect further adds to its appeal.

Aluminum PCB manufacturing

Aluminum PCB Manufacturing: Structure of Aluminum PCB

The copper-clad laminate (CCL) is the basis of the aluminum PCB structure. It consists of the aluminum membrane, aluminum base, dielectric layer, and the copper foil. In the picture below, you can see the structure of the copper-clad laminate.

Copper Foil layer

The Aluminum CCL has the same copper foil layer as that of any other type of PCC’s CCL. It is the current’s objective to provide a large current carrying capacity. Due to this, choosing a thick copper circuit is a good decision in aluminum PCB manufacturing.

Generally, the manufacturer prefers the thickness between 1oz to 10oz. It is important for the copper foil’s backside to go through different oxidation treatment. The treatment involves chemicals as well.

Likewise, the front side goes through brass plating and zincing. The main reason for front treatment is to improve the peel-off strength of the aluminum Printed Circuit Board.

Dielectric Layer

The next layer, is the dielectric layer. It compromises of a composed thermal dielectric material. This material has a low thermal resistance. Generally, it has a thickness ranging from 50μm to 200μm. The thickness depends upon the type of the Printed Circuit Board and the consumer’s demand.

This layer seems to be the aluminum Printed Circuit Board core technology. It has the same functionality as that of the anti-thermal aging. Moreover, it has the capacity to withstand thermal stress as well as mechanical stress.

Aluminum Base Layer

When we say aluminum base layer, we actually mean the aluminum substrate. This substrate is supporting all the components present on the board. It binds the components to the board. It is imperative for this substrate to be highly thermally conductive.

Base layer also needs to be suitable for the different mechanical processes including cutting, punching, and drilling.

Base Membrane

The aluminum base pays an important role in the protection of PCB’s aluminum surface. It ensures that the surface is safe from agent etching and scraping. There are two main types of base membrane, first ordinary and second anti-high temperature.

Ordinary membrane usually withstands temperature lower than 120°C. On the contrary, the anti-high temperature can withstand up to 250°C.

The anti-high type is the best choice for hot air solder levelling.

Aluminum PCB Performance

Before is the performance of the aluminum Printed Circuit Board.

Thermal Dissipation

There is no denying that aluminum PCB performs efficiently in terms of thermal dissipation. These Printed Boards have the capability to dissipate heat effectively in comparison to the regular Printed Board.

Let us take an example to further demonstrate our point. Take Aluminum Printed Board along with an FR4 Printed Circuit Board. Both these boards have the same thickness i.e. 1.5mm. Despite having the same thickness, Aluminum PCB would offer a thermal resistance of 1°C/W to 2°C/W.

On the other hand, the standard Printed Circuit Board would offer between 20°C/W to 22°C/W. This clearly illustrates that Aluminum PCB is way ahead of the standard boards in case of thermal dissipation.

Thermal Expansion

Contraction and thermal expansion are the nature of every substance. However, the amount of expansion and contraction greatly depends upon the material. There is a different thermal expansion coefficient of every material.

Aluminum is an excellent choice in this regard as well. It works smoothly for contraction and the thermal expansion problem of the surface mount technology. These PCBs are completely reliable and they increase the durability of the Printed Board.

After, thermal expansion is a great problem at the aluminum PCB manufacturing end. Resolving this issue would make the Printed Circuit Board robust.

Dimensional Stability

Aluminum PCBs ensure performance because they offer a stable size. Even when you heat the Printed Circuit Board from 30°C up to 150°C the expansion rate is between 2.5% to 3.0%.

Other Performance Factors

If you think that the benefits of Aluminum Printed Circuit Boards end above, you are mistaken. There are several other performance factors that make a good and reliable Aluminum PCB Manufacturer claim. Some of these factors are below.

  • Aluminum Printed Circuit Boards are important for Surface Mounted Technology’s Power Devices.
  • It is extremely efficient in terms of the expansion of the circuit design. This then, makes the desired device more reliable and efficient.
  • Aluminum Printed Boards are also famous for improving overall product density.
  • These boards have the capacity to effortlessly reduce operating temperatures.
  • Their effective thermal expansion prolongs the ling of the product. Thus, improving the brand image.
  • Aluminum PCB manufacturing is popular because of its cost-effective assembling.
  • They help to decrease the hardware, which then results in a lower cost of the Printed Circuit Board.
  • Their base is strong then the usually ceramic base. The base has proper mechanical endurance and great insulating property.

Choosing Aluminum PCB Manufacturing Company

Aluminum Printed Circuit Boards are reliable and efficient. However, the quality of the board greatly depends upon the manufacturer. When you choose a reliable manufacturer, you will have high-quality Printed Boards.

Miracle BWB is the leading manufacturer. They have been in business long enough to understand all the ups and downs. Manufacturers are able to generate effective and high-quality Printed Circuit Boards in limited time.

They are the leading Aluminum PCB manufacturer because they have skilled and component people on board. These people would help you design and develop top-notch quality, reliable, effective, and efficient Printed Circuit Boards for your electronics.

Aluminum PCB manufacturing in china

Take Away

Aluminum Printed Circuit Boards are the leading Board in the industry due to their performance factors. They are reliable and have outstanding thermal conductivity capacity. Their limited thermal expansion makes them the best choice for SMT power devices.

Incorporating aluminum Printed Circuit Boards into your devices would not only enhance their performance, but it would also increase their shelf-life. Reliable products, with increased shelf-life and efficient functioning eventually enhance brand image and increases leads.

Therefore, it is imperative to have only the best quality printed Circuit Boards incorporated into your electronics. After all, the objective is to not only attract new consumers but to retain your old ones as well.

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