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What is the Metal Core PCB Difference Between Aluminum

PCB and Copper Base PCB?
What is the difference between Copper base PCB and Aluminum base
PCB? MCPCB has a metal base with superior thermal conductivity and better heat
dissipation. You can find both types of PCBs in any electronics store. Learn what
makes them different and choose the best material for your project.

Table of Contents

What is Aluminum PCB?

Before determining what an aluminum PCB is, we need to understand its main
characteristics. These include Thermal conductivity, Dielectric layer,
Electrical insulation, and flexibility. The following sections explain these qualities in
greater detail. Read on to learn about the advantages of this material! Also, read about
the benefits of insulating a PCB with aluminum.

Thermal conductivity

The thermal conductivity of aluminum PCBs varies according to the copper layer in
the circuit. Different processes will result in different levels of thermal conductivity.
Aluminum has poorer thermal conductivity than PCB board. Thermal conductivity
also depends on the aluminum substrate and pad design. Copper foil and aluminum
plates are typically laminated together to create a single board. The thermal
conductivity of aluminum PCBs can vary remarkably. The following are some
characteristics to consider when selecting an aluminum-based PCB:

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Aluminum PCB Applications

The thermal conductivity of aluminum PCB is higher than that of copper. However, it
is still not as high as copper. This is because aluminum is thinner than copper, and
copper is much denser. Therefore, a thicker aluminum PCB will be more resistant to
heat, while a thin aluminum one will have less resistance. These properties will
reduce breakdown voltage, so aluminum PCBs should help low-voltage applications.

Aluminum PCBs have excellent electrical insulation and thermal conductivity. This
means they can carry more current than other materials, including FR-4. In addition,
because of their thermal conductivity, they can withstand higher temperatures than
other materials. The thermal conductivity of aluminum PCBs enables Rayming PCB
& Assembly to make more efficient electronic circuits. Moreover, aluminum PCBs
can be more durable than FR-4, prone to damage.

Aluminum PCBs are often helpful in lighting and electrical devices. To extend its
lifespan, make sure to store them in a dry, dark place. They can yellow or blacken due
to moisture. The best way to store aluminum PCBs is to use them within 48 hours
after removing them from their vacuum packaging. If you are unsure of what to do
with your aluminum PCBs, consult with an experienced electrical engineer.

Dielectric layer

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An aluminum PCB has an interior dielectric layer composed of a ceramic or

thermally conductive material. A thermally conductive dielectric layer helps manage
the heat in a project while keeping the temperature within specified limits. Typical
thicknesses of dielectric layers range from 0.05 to 0.2 mm. In addition to the dielectric
layer, an aluminum membrane layer protects the aluminum core and is crucial for the
proper function of the IC.

A dielectric layer consists of copper or aluminum foil. Its thickness varies depending
on the requirements. Copper-clad laminates generally have a copper base layer that is
50mm thick. The metal base layer is also thermally conductive. The aluminum base
layer has high thermal conductivity and a copper foil layer that is 50 to 200mm thick.

An aluminum PCB with an insulating dielectric layer is excellent for several

applications. These PCBs offer dimensional stability and are suitable
for power device surface mount technology. Additionally, aluminum PCBs reduce the
overall volume of the product. They also exhibit superior reliability. They can also
help prolong the shelf life and increase its power density. And since aluminum is
cheap, this material makes it a good choice for manufacturing power electronics
products.

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Electrical insulation

The insulating layer consists of electrolytic copper foil with a thickness of one to ten
ounces. A ceramic polymer serves as a critical module of a PCB and has excellent
thermal and viscoelastic properties. Therefore, copper foils, anywhere from one to ten
ounces in weight, are in the insulating layer.

An aluminum PCB’s high-voltage test ensures its complete electrical insulation. It

must pass a high voltage test that measures 100 percent of the printed board’s surface
area. When a PCB fails a high voltage test, it will likely experience leakage, fire, or
malfunction. Delamination and blistering of the aluminum base are defects in an
aluminum PCB. As a result, you should ensure that your aluminum PCB passes these
tests.

Metals are highly conductive, so it’s essential to protect your PCB from accidental
conductivity. While it is a good conductor of heat, it also conducts electricity. In some
situations, metal substrates are necessary because they can handle powerful electrical
currents. However, this doesn’t mean that a PCB without any insulation will fail, even
if it’s just slightly conductive. Ultimately, it’s essential to match the electrical
insulation on your PCB with the environment in which you intend to use it.

In addition to aluminum PCBs, copper PCBs are another way to make

thermally-efficient circuits. Copper-based PCBs work as a central core of a complex

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thermal structure. Still, aluminum is also an excellent choice for this application
because it can provide outstanding electrical insulation and excellent thermal
conductivity. The aluminum PCB’s copper-based circuit layers consist of a
metal-based copper-clad laminate and excellent electrical insulation.

Flexibility

The process for manufacturing flexible aluminum PCB includes multiple thermally
conductive dielectric materials. They connect to the circuitry layers using signal
and thermal vias. They are also composed of ceramic filters and polyimide resin. This
material provides high flexibility and remarkable thermal efficiency.

The flexibility of aluminum PCBs allows them to bend during installation. They are
available in single, double, and multi-layer layouts. They are used to replace bulky
wiring with superior gear. Flexible aluminum PCBs are also available with higher
thermal performance.

The flexibility of aluminum PCB depends on its construction and conductive layers. It
also depends on plated through holes for connection. The more flexible aluminum
PCBs you order, the more money you’ll save. It’s also a great option if you have
space constraints. If you have limited space, flexibility is essential for your device.
It’s worth the extra cost. And it’s also a good option for many applications.

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Applications

The use of aluminum PCBs has several benefits for circuit designers. Due to its
increased thermal conductivity, it provides better electrical insulation. Its thin-film
dielectric layer also helps to remove heat from the circuit. Copper foil is one of the
primary components of aluminum PCB. Using this material is an environmentally
friendly choice but requires proper expertise in the manufacturing process.

Another benefit of aluminum PCBs is that they are less susceptible to damage from
moisture and heat. In the case of a cooling system, it can replace a ceramic
substrate or a radiator component. Aluminum PCBs can also help in
automobiles, audio equipment, and power supply devices. The power supply
applications include switching regulators, DC/AC converters,
and high-frequency amplifiers.

In addition to the advantages of aluminum PCB, it is also lightweight and low-cost.

We can make it into various shapes and thicknesses according to the user’s needs.
There are several types of aluminum PCB: through-hole, flexible, and multi-layer.

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They have their advantages and disadvantages. You should consider the pros and cons
of aluminum PCBs before deciding.

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What is Copper Base PCB?

Copper Base
PCB

You may be wondering: What is copper base PCB? A PCB is an electronic

circuit board containing copper as one of its constituent elements. There are different
PCBs, and they all have their benefits and drawbacks. For this article, I will compare
copper-based PCB and MCPCB. You’ll need to know the basic differences between
the two types to do this.

MCPCB

The basic design of an MCPCB consists of a copper core, a thermal insulating layer,
IC components, and a solder mask. This design is also a COB MCPCB or
“Chip-On-Board” PCB. Copper is more expensive than aluminum, unlike aluminum
PCB, making it an economical option for some applications.

MCPCBs have many advantages over other PCB types. First, MCPCBs does not
require vias for thermal relief, which makes them ideal for high-heat applications.
Second, MCPCBs require much less drilling than other PCBs, which only need a few
large holes to mount components. Finally, these are also known to be more durable
and withstand repeated mechanical shocks and thermal cycles.

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Another advantage of MCPCB is that it allows for better etching. For example, we
can etch Copper-based PCBs into a boss shape, which is excellent for pasting
components. In addition, copper has a different modulus of elasticity than aluminum,
making them more stable than aluminum PCBs. This is an essential advantage when
comparing copper-based vs. aluminum-based PCBs.

MCPCBs are also cheaper than FR4 and aluminum-based PCBs. However, they
require a higher level of precision and cost. Aluminum-based PCBs are less expensive
than copper-based PCBs and are generally helpful in areas with high requirements.
On the other hand, a copper-based PCB can handle temperatures as high as 450
degrees Fahrenheit.

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Copper base PCB

If you’re planning to use a copper base PCB in your electronic device, it’s essential to
know more about it before you order it. The term “copper base” can refer to
any electronic board. While “copper” may not be the most familiar, it is an excellent
option for electronic circuit boards.

Unlike the usual single-sided PCB, double-sided metal-core PCBs use a metal core
between two conductors layers. The copper layer sits between the two conductor
layers, with the metal core connected to the conductors through vias. Unlike the other
two types, a copper-core PCB can withstand high temperatures.

Copper-based PCBs are the most expensive type of metal core PCB. They are also
more expensive than their aluminum and iron-based counterparts. However, they
perform better in heat conduction and thermal diffusivity and are ideal for
high-frequency circuit design, high-heat-dissipation circuits, and high-precision
communication equipment.

A copper-based PCB is also commonly known as an MCPCB. It’s a printed circuit

board with a metal core and insulation layer. It has superior heat-dispersing properties
and superior mechanical strength. Aluminum-based PCBs are more cost-effective
than copper-based ones. Copper-based PCBs are often used in electronic
communication equipment and LED lighting, among other things.

Compared to aluminum, copper has a higher conductivity rating than aluminum. In

addition, its density makes it ideal for multiple-layer PCBs. On the other hand,
aluminum is an excellent choice for single-layer PCBs but is less efficient for
multi-layer PCBs. Besides, aluminum has a much lower carbon footprint than copper.
Therefore, if you’re considering copper-based PCBs for your products, ensure you get
a PCB with a heavy copper base.

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MCPCB symmetry

We achieve the symmetry of MCPCB multiple set-ups containing a metal core by

having similar-thickness layers over and beneath the board’s metal backing. A
six-layer board, for example, would have three layers above and below the metal
backing. In addition, it is essential to avoid the warpage or MCPCB LEDs.
Additionally, plated through-holes are unnecessary because they can lead to electrical
shorts and poor performance.

The copper PCB is often embedded with other circuitry to improve performance and
reliability. For example, electronic device manufacturers use MCPCBs with copper
cores. The copper track between components makes it possible to fit the PCB in a
small device. This type of PCB is more expensive than those with aluminum cores,
but they are also stronger and more reliable.

The metal base layer helps dissipate heat and enables the copper foil to create the
desired pattern. Copper base PCBs are the most expensive type of MCPCB and use
copper substrate core technology. Therefore, the copper base PCB is the costliest type
of MCPCB, but it has the highest thermal conductivity.

To design an MCPCB, you must know how copper conducts electricity and heat. To
achieve this, you must have a high-density copper foil at least 35mm thick. Copper
foil with low conductivity will cause a short and will have to be isolated from the
copper base.

While a metal core PCB has a metal core and insulation layer, the metal base PCB is
not much different from a CEM3 or FR4 board. However, it has a metal copper film
core in the middle or on the back, which can divert heat away from the heat-sensitive
parts of the PCB. It also has better processing capabilities compared to other types of
PCB.

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Aluminum PCB VS Copper base PCB

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What is the difference between an Aluminum PCB and a Metal Core PCB? A PCB
made with a Metal Core is a higher quality version. For this type of PCB, the main
substrate board consists of a Metal Core. It also contains a copper layer. However,
unlike an Aluminum PCB, a Metal Core PCB does not receive any surface finish or
solder mask.

Copper printed circuit boards are used in high-power rectifiers and pumping plants to
ensure high power. Their superior electrical and thermal conductivity makes them
suitable for the smallest electronic devices. While copper printed circuit boards have
many advantages over aluminum, they still need a copper base for a few important
reasons. Copper PCBs are also more expensive than aluminum and iron PCBs.

Prototyping a Metal Core PCB is like prototyping and Aluminum PCB. The basic
process of prototyping starts with a design software suit. When you decide to use a
PCB manufacturer, you should know the software they use for prototyping. Metal
Core PCB manufacturers should also know which software they use for prototyping.

The difference between Copper and Aluminum PCBs is most evident in how copper
has higher thermal conductivity and is, therefore, more suitable for single-layer PCBs.
On the other hand, aluminum is much more difficult to manufacture for multiple-layer
PCBs. Therefore, copper is the ideal metal for multiple layers. In addition to being
lighter, aluminum is also better for environmentally friendly reasons.

MCPCB has a metal base

The term “Metal Core PCB” refers to the base material. The main substrate board is
composed of a metal core. A metal mask is applied to the board before the soldering
process begins. The solder mask includes a copper base and black and clear printed
circuit boards.

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A prototype of a metal core printed circuit board is a lot like a typical PCB. It requires
a metal base and must adhere to certain guidelines. The final figure of the circuit
board should resemble the design. Different design software is ideal for this purpose.
For example, OrCAD, Altium Designer, KiCAD, Eagle, and KiCAD are popular
choices. Once the design is complete, designers export schematics to the PCB
manufacturer. Gerber is an essential tool for forwarding schematics because it
preserves the aesthetic appeal of the PCB.

The base of a Metal Core PCB serves as a heat sink, transferring heat away from
critical components. Different metals can be the base of a PCB. Aluminum is the most
common, but copper is the best for performance, although it is also the most
expensive. The base is typically 1 to 4 mm thick, depending on the customer’s
requirements. This layer is often the first layer of a PCB.

Metal Core PCBs are ideal for high-temperature applications, such as amplifiers and
solid-state relays. Because metal is thermally conductive, it helps dissipate heat
efficiently, ensuring that the device’s life span and performance remain high. In this
way, the metal core PCB is perfect for these high-temperature conditions. And unlike
the FR-4, the MCPCB can withstand the highest temperatures in the market.

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MCPCB has excellent heat dissipation

In electronics, thermal management is an important consideration. Temperatures that

exceed the acceptable range can cause physical destruction and system failure.
Metalcore PCBs are ideal for applications requiring high thermal dissipation. This
type of PCB has several advantages. Its high thermal conductivity, 1.6 mm thickness,
and 270 mm2 board size make it a better choice for many applications.

Due to their superior heat dissipation, metal core PCBs are helpful in various
applications. They are particularly suited for power electronic devices, such as
high-drain-current MOSFETs, switching supply circuits, and LED light circuits.
Metalcore PCBs have a basic configuration of conductive layers that facilitate heat
dissipation.

The process for producing an MCPCB is like the standard FR4 PCB. The only
difference is the material used for the layers. For example, FR4 is a very strong
material. Therefore, an MCPCB has excellent heat dissipation properties despite its
high density. Moreover, MCPCBs does not require vias, leading to shorts or other
problems.

The main applications of Metal Core PCBs include solid-state relays, LED lighting,
and motor control in electric vehicles. Metal PCBs are ideal for applications that
generate heat. They also perform better than traditional FR-4 substrates for fast

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cooling. The most used metal layer is aluminum, which is very conductive.
Aluminum is also non-toxic, recyclable, and possesses a high thermal conductivity.

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It has a better thermal conductivity

There are many advantages to a Metal Core PCB. It is known for its better thermal
conductivity, and it can redirect heat away from electronic components. It is one of
the best PCB substrates, and its superior thermal conductivity makes it an excellent
choice for many electronics. Aluminum is one of the most used metals used for PCBs.
Copper and aluminum both offer better thermal conductivity than FR-4.

Metalcore PCBs are helpful in applications that generate enormous heat and cannot be
cooled using conventional fans. They are used to achieve high illumination with fewer
requirements than traditional LEDs. They are also helpful in military and aerospace
applications, which must withstand thermal cycling and repeat mechanical shocks.
This makes them the perfect choice for such demanding uses. Furthermore, MCPCBs
are more durable than normal PCBs, susceptible to damage due to heat and moisture.

Different manufacturers fabricate their boards differently for Metal Core PCBs. For
example, a simple one-layer MCPCB has a copper circuit layer at the top, a thermally
conductive dielectric layer underneath, and a metal core base layer. The fabricator
then assembles these three layers. The copper and aluminum layers provide an
efficient path for heat from electronic components to reach the circuit board.

High-power components produce a large amount of heat, making it necessary to

transfer the heat as fast as possible. Hence, metal core PCBs are popular in the power
supply and converter industry, LED lighting systems, and automotive systems. In
addition, they are better suited to resist heat transfer than FR-4 PCBs, preventing
damage to the circuit and components. For these reasons, it is essential to make sure
that the PCB you use has an excellent thermal conductivity rating, as this will increase
the life of your product.

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It has a symmetrical stack-up

When designing a metal core PCB, it is essential to follow several design guidelines.
As its name suggests, a metal core is a layer of metal attached to the back of a PCB.
Usually, this layer is made of aluminum, although copper and stainless steel are also
possible materials.

When designing a metal core PCB, it is essential to avoid plated through holes. As
these holes can short circuits, isolating the metal layer from the plated through-hole is

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essential. A hole in the metal core is drilled 40 to 50 mils larger than the plated
through-hole component, filling it with a non-conductive epoxy filler.

The conductive layers in the PCB stack-up are in an alternating pattern, with the
top-most conductive layer 102A positioned above the bottom-most prepreg layer
104G. The same applies to the insulating layers. As a result, the stack-up is
symmetrical, and the structure of the PCB is also symmetrical.

Related Posts:

1. Metal PCB Materials Differences: Aluminum Vs. Copper Core Vs. Iron
Based

2. Top 18 Ceramic PCB Manufacturers in The World

3. Building the Multilayer Metal Core PCB

4. PCB Thermal Conductivity Performance: FR4 Vs. Ceramic Vs. Metal

Core Vs. Rogers

https://www.raypcb.com/aluminum-pcb-vs-copper-base-pcb/

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