Metal Core PCBs
Expertise in PCB Manufacturing
Expertise in PCB Manufacturing
- Materials: High-quality Copper & Advanced High-Thermal-Conductivity Dielectric
- Layer Count: 1 to 8 Layers
- Minimum Drill Size: 0.3mm
- Copper Thickness: 0.5 to 10 oz
- Minimum Trace Width/Space: 0.1mm
- Advanced Technologies: Standard & Thermoelectric Separation Techniques
Advantages of Copper-Based PCBs
- Superior Thermal Conductivity: Offers thermal conductivity of up to 400W or more, making it ideal for high-power applications.
- Outstanding Processability and Dimensional Stability: Ensures precise manufacturing and consistent performance under demanding conditions.
- Cost-Effective Alternative: Compared to ceramic circuit boards, copper-based PCBs offer a more budget-friendly solution without compromising quality.
- Excellent Machinability and Aesthetics: Provides ease of machining, a sleek appearance, and flexibility in design.
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Understanding Copper Based PCBs
A Copper-Based PCB is a specialized type of metal-core PCB, utilizing a copper substrate for enhanced thermal performance. As the leading material in thermal conductivity among metal-core PCBs, copper-core PCBs offer thermal conductivity of up to 400 watts, making them ideal for high-power applications. They effectively address heat-related issues such as high power dead lights, significant light decay, and excessive heat generation, particularly in LED lighting.
Copper-Based PCBs, along with aluminum-based PCBs, are widely recognized for their advantages and are commonly used in various high-power applications, including automotive systems, stage lighting, control panels, photographic lighting, projection lights, and laser lamps.
These PCBs are integral to high-performance electronics, offering superior thermal conductivity and heat dissipation. Copper-Based PCBs are crucial for applications that demand efficient thermal management, such as LED lighting, power electronics, and high-frequency circuits, ensuring reliability and longevity in even the most demanding environments.
ufacturing
Copper-Based PCBs: Features and Benefits
Copper-based PCBs are renowned for their superior performance, particularly in advanced and high-tech applications. Among the various substrates used for PCB manufacturing, copper stands out for its exceptional qualities, making it the most effective—albeit the most expensive—option. Here’s a closer look at the key features of copper-based PCBs:
Exceptional Thermal Conductivity
Copper-based PCBs excel in thermal management, a critical feature for high-performance electronics. The thermal insulation layer, composed of silicon powder, aluminum oxide, and epoxy resin, plays a vital role in enhancing heat dissipation, making copper an ideal choice for products that generate significant heat.
Superior Electrical Conductivity
Copper PCBs offer excellent electrical conductivity, enabling them to handle large currents efficiently. To prevent overloading, thicker copper foils—typically ranging from 40μm to 290μm—are used, ensuring the PCB operates flawlessly under demanding conditions.
Outstanding High and Low-Temperature Resistance
Copper PCBs are highly resistant to both extreme high and low temperatures, making them suitable for industries such as communication electronics and industrial construction, where thermal resilience is critical. This thermal stability is complemented by excellent electrical conductivity, ensuring reliable performance in high-frequency applications.
Enhanced Mechanical Heat Resistance
Through extensive production experience and material expertise, it’s evident that copper PCBs offer improved viscoelasticity, heat resistance, and aging resistance. These boards demonstrate low thermal resistance and superior mechanical heat resistance, making them ideal for applications requiring durable and long-lasting components.
Flexibility and Processability
Copper plates, commonly used in copper-based PCBs, offer remarkable flexibility. This flexibility allows for easy mechanical processing, such as drilling and cutting, without compromising the board’s integrity. Additionally, the excellent thermal and electrical conductivity of copper ensures optimal product performance.
Ideal for High-End and High-Tech Products
Due to their superior characteristics, copper-based PCBs are often used in high-end and high-tech products. While the cost of copper-based boards is higher due to the complex manufacturing process and premium materials, their unparalleled performance makes them the preferred choice for cutting-edge applications.
Key Considerations in Copper-Based PCB Production
Copper core PCBs are crucial in the electronics industry, particularly for high-end applications. As technology continues to advance, the demand for copper-based PCBs is expected to grow due to their superior thermal and electrical conductivity, which justifies their higher cost. However, the production of copper-based PCBs is more complex than that of traditional FR4 PCBs, requiring special attention to detail. If you’re looking to manufacture copper core PCBs, feel free to contact us anytime.
Resin Filling Depending on the application, solid or liquid resin can be used to fill the holes in copper core PCBs. During this process, resin is heated and melted to flow into the holes, ensuring they are properly filled without the need to clean the resin from the board surface.
Lamination Design Proper lamination design is critical in copper core PCB production. For example, if a finished board thickness of 1.6mm is required, the copper base should be 1.2mm, with a finished copper thickness of 1OZ. Selecting the right materials and parameters is essential to achieving the desired board specifications.
Lamination Process Lamination is a key step in copper-based PCB production and must be carefully managed. The process parameters should consider factors such as resin hole air exhaust, resin curing, and copper heat transfer to ensure optimal results.
Drilling Design After lamination, the PCB undergoes processing. Special copper drills are required for through holes that pass through the inner copper base. Drilling speeds should be kept below 25,000 rpm, with a feed rate of no more than 0.5m/min to avoid damaging the material.
Large Hole Drilling For heat dissipation holes, specialized copper substrate drills are used. The rotation speed should not exceed 15,000 rpm, and the feed rate should be limited to 3m/min to maintain precision and avoid defects.
Surface Copper Thickness Control Controlling surface copper thickness is a critical aspect of copper-based PCB fabrication. The optimal surface copper thickness is 35μm, with a tolerance of less than ±5μm. This ensures the board meets performance requirements.
Electroplating To ensure uniform copper thickness, full-board electroplating is recommended. After the PTH (plated through-hole) process, copper electroplating thickens the surface copper to 35μm, followed by circuit creation, tin resist plating, and etching.
Uncovering Before tin spraying, the bending position must be exposed. The uncovering process involves removing the outer layer along the bending line, exposing the copper at critical points, including any screw holes.
Surface Treatment Surface treatments such as HASL, OSP, or ENIG are applied to prevent oxidation and enhance solderability. Lead-free HASL, typically at 270°C for 3-4 seconds, is commonly used, with care taken to avoid respraying tin on the copper substrate to prevent defects like blowholes or thin copper layers.
Bending The final step involves bending the copper-based PCB to the specified dimensions, following the direction and angle indicated in the design. Bending is typically done at a 90° angle unless other specifications are required.
Choose LEAPPCB as Your Copper-Based PCB Partner
In need of copper-based PCBs? Look no further! LEAPPCB is your trusted partner for high-quality and reliable copper PCB solutions. We specialize in delivering top-tier copper-based PCBs that meet the specific requirements of your applications.
Expertise in Copper-Based PCB Manufacturing
At LEAPPCB, we excel in the production of metal-core PCBs, including copper and aluminum substrate boards. With a commitment to short lead times, stringent quality control, and exceptional customer service, we ensure that your copper-based PCB needs are met with precision.
Reliability and Trust
Equipped with advanced automated production facilities and professional testing instruments, LEAPPCB is dedicated to providing you with flawless copper PCB services. Our focus is on fabricating high-performance, reliable copper-based PCBs that you can depend on.
Customer-Centric Approach
We prioritize understanding your specific requirements for copper core PCBs and strive to exceed your expectations. Our goal is to deliver high-quality, cost-effective products on time, ensuring your satisfaction at every step.
Commitment to Quality
At LEAPPCB, quality is at the heart of everything we do. We leverage advanced copper core PCB fabrication technology, efficient operations, and a relentless pursuit of excellence to provide you with the best possible products and service.
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Leap Electronic is your trusted partner and one-stop shop for PCB fabrication, component sourcing, PCB assembly, and electronic manufacturing. With over 16 years of expertise, we proudly serve over 1000 customers worldwide, delivering top-quality PCBs at competitive prices. Our ISO9001:2015 certification and UL listing ensure that all our products meet the highest industry standards. Every PCB is 100% E-tested and inspected using AOI and X-RAY, guaranteeing unparalleled reliability and performance.
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Everything You Need to Know About Copper Based PCBs
- Superior Thermal Conductivity: Ensures efficient heat transfer in high-performance applications.
- High Heat Conduction Efficiency: Facilitates optimal thermal management.
- Excellent Heat Dissipation: Keeps components cool, enhancing reliability and longevity.
- Good Machinability and Dimensional Stability: Allows precise manufacturing and consistent performance.
- Large Current-Carrying Capacity: Supports high-power applications effectively.
- Automotive Systems
- Telecommunications Equipment
- Industrial Control Systems
- Medical Devices and Sensors
- Security Systems
- Aerospace and Military Applications
- LEDs and Lighting
- Complex Manufacturing Process: More intricate compared to standard FR4 PCB production, requiring specialized techniques such as outline profiling and cutting.
- Higher Cost: Copper-based PCBs are more expensive than traditional FR4 boards.
- Limited Layer Count: Typically designed with only one or two signal layers, making them less suitable for multilayer PCB designs.
Yes, alternatives such as aluminum, alloy compounds, reinforced FR4, and other advanced PCB materials are available. It’s advisable to consult with your PCB designer or manufacturer before opting to switch from copper to another substrate.
If your electronic devices demand extremely high thermal conductivity and efficient heat dissipation, copper-based PCBs are an excellent choice.
Is There a Difference Between Copper Metal Core PCBs and Copper-Based PCBs?
The first step is to select the appropriate material based on your application’s requirements. Collaborating with your PCB manufacturer during the design phase is crucial for optimal results.
- Follow ISO 9001 standards throughout the production process.
- Use insulated tools to handle copper-based PCBs safely.
- Store copper PCBs in a temperature and humidity-controlled environment to prevent oxidation.
Copper-based PCBs should be stored in environments with low relative humidity and within a specific temperature range to prevent oxidation. They should also be kept in static-free packaging or containers made from non-conductive materials.
No, there is no difference. Both terms refer to circuit boards with a copper substrate designed for efficient heat dissipation in high-power electronics.
Yes, although most copper foil-based PCBs are single-layer, some advanced electronic devices require multilayer metal core PCBs. Manufacturing these requires a highly experienced production and quality team.
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