What is Aluminum PCB?
Among all metal core PCBs, aluminum PCBs are the most common type. The base material consists of an aluminum core combined with standard FR4. It features a thermal clad layer that efficiently dissipates heat, cooling components and enhancing the overall performance of the product. Currently, aluminum-backed PCBs are regarded as the ideal solution for high-power and tight-tolerance applications.
Price Comparison
FR4 PCBs are widely used in the electronic industry and are considered the standard. However, in the LED industry, FR4 is less common than aluminum PCBs, which are preferred due to their superior heat management. This is why many people mistakenly refer to aluminum PCBs as “LED PCBs.”
Due to the increased focus on thermal management, aluminum PCBs need to handle more heat compared to conventional PCB designs. Additionally, the metal materials used in aluminum PCBs are more expensive, making them typically pricier than FR4 PCBs.
Heat Performance Comparison
In traditional PCB design theory, electrical performance is prioritized first, followed by layout considerations. Aluminum PCB design, however, involves additional attention to heat transfer.
In LED lighting applications, heat buildup is a significant challenge. Using high-performance metal materials in aluminum PCBs can address this issue, improving overall thermal management compared to FR4 PCBs.
The Stack-Up of Aluminum PCB vs. FR4 PCB
After comparing price and performance, let’s discuss the construction or stack-up of aluminum PCBs. Aluminum PCBs typically consist of three layers. In contrast, FR4 PCBs can have a varying number of layers (1, 2, 3, or more) depending on the application. The most significant difference between aluminum PCBs and FR4 PCBs lies in the dielectric layer. Aluminum PCBs are better at heat management due to this specialized dielectric layer.
Application Comparison
FR4 PCBs are used more widely than aluminum PCBs across many industries. However, in the LED industry, engineers typically choose aluminum PCBs for new projects due to their superior thermal performance.
For instance, a single-layer aluminum PCB has an aluminum core as the base, with a copper layer on top and a dielectric layer in the middle. Aluminum PCBs are preferred over traditional FR4 or CEM3 PCBs because they efficiently dissipate heat from components, thanks to the thermally conductive dielectric layer.
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