Copper Base PCB

In metal core PCBs, designers may choose from three different materials for the PCB core: copper, aluminum, or iron-based PCBs. These materials are ideal for high-powered electronic components that require efficient heat dissipation, leading to an increase in demand for metal core PCBs.

In high-power and high-frequency PCB designs, designers often use copper-based PCBs due to their processing capabilities. However, to handle high current flow, such designs require a high current carrying capacity, which necessitate a thick copper foil. Typically, copper foils with thicknesses ranging from 35μm to 280μm are utilized.

PCB Manufacturers can etch copper-based PCBs into fine patterns and subsequently transform them into the shape of a convex platform. Connection to the platform can dramatically enhance both heat and grounding dissipation. Thus, this must be considered while designing these PCBs.

What is a Copper-based PCB?

Copper-based PCBs are the most expensive in the metal PCB category, known for their superior thermal conductivity surpassing aluminum and iron-based PCBs. This makes them ideal for sophisticated communication equipment designs, architectural decoration industries, and high-frequency circuit designs, as they can endure extreme low and high temperatures.

Copper-based PCBs come in a range of varieties such as immersion gold copper-based PCB, silver plating copper-based PCB, high-air soldering layering (HASL) Copper-based PCB, anti-oxidation copper-based PCB, and more.

Due to the high current demands on copper-based PCB layers, thicker copper foils are utilized, which necessitate thermal conductivity insulating layers. These layers are primarily composed of a blend of epoxy resin, silicon powder, and aluminum oxide.

Copper-based PCBs provide several advantages, including a low thermal resistance of 0.15, and good viscoplastic properties. They can withstand thermal aging, thermal and mechanical stress, and have a crucial role in dispersing heat and shielding and grounding of the copper-based PCBs. The metal substrate is an essential support component of the copper-based PCB, facilitating efficient heat conduction during mechanical processes such as drilling, punching, and cutting.

Substrate of Copper Core PCB

Copper PCB, also known as copper substrate PCB, copper base PCB, or copper-clad PCB, consists of an insulating layer substrate and a Copper circuit layer on top. Although polypropylene (PP) is an excellent insulator between the base layer and the circuit layers, it hinders heat sinking. In comparison, copper has superior thermal conductivity over aluminum base PCBs. Hence, regular copper base PCBs have higher electrical conductivity than aluminum PCBs of the same thickness and number of layers.

Our printed circuit board manufacturing factory produces various copper PCBs tailored to suit our customers’ needs. These PCBs are appropriate for power supply and high-power LED applications, such as 1000W+ lighters.

In the realm of LED lighting you’ll come across four varieties of copper circuit boards：

● The direct thermal pathway without a dielectric layer is an aluminum-copper PCB. This type of PCB is designed to provide a direct thermal pathway without an insulating dielectric layer between the aluminum base and copper traces, enabling quicker dissipation of heat. The aluminum substrate provides excellent thermal conductivity properties, while the copper traces enable efficient electrical current carry capacity. Consequently, these PCBs are ideal for high power LED lighting and other applications requiring efficient heat dissipation and high power handling capabilities. Our PCB manufacturing facility produces these aluminum-copper PCBs to meet the specific requirements and demands of our clients.

● The COB Copper PCB (Chip on Board Copper PCB) is specifically designed to allow for a direct thermal sink to the copper substrate from the LED chip. In this configuration, the LED chip is directly mounted on the copper substrate, allowing for optimal heat dissipation. This design is particularly suited for high-power LED applications where effective heat dissipation is a critical factor in ensuring optimal performance.

As a specialized PCB manufacturing company, we produce COB Copper PCBs customized to meet the specific requirements of our clients. Our COB Copper PCBs are ideal for use in high-power LED applications where efficient thermal management is essential to ensure maximum performance and longevity.

● The Normal stack-up Copper PCB with a Core PCB is fabricated utilizing a conventional construction scheme that includes a copper trace layer and insulating dielectric layers. Additionally, a copper core PCB layer is inserted to improve the thermal conductivity of the PCB to up to 12 W/m.k. This construction is particularly suited for high-power applications where thermal management is a vital factor to ensure maximum performance and longevity.

● The proposed setup features an unmediated thermal pathway, with the absence of any dielectric layer underlying the pertinent thermal pad.

Copper Base PCB Design Considerations

When creating a Copper Base PCB it’s important to consider the following:

● Thermal management: As Copper Base PCBs are intended for high power uses effectively managing heat dissipation is crucial.

● Electrical and mechanical needs: Ensure that the design meets all the required mechanical specifications, such as voltage, current and dimensions.

● Choosing materials: It’s important to thoughtfully select materials, for the base insulating layer and surface coating of the PCB as they play a crucial role in its performance and longevity.

● Positioning components: When arranging the components, on the PCB it’s crucial to think about their placement to maximize heat dissipation and avoid any interference issues.

● Ground plane design: The use of a solid ground plane can improve heat dissipation, reduce electrical noise, and provide mechanical support.

● Signal routing: Careful consideration it’s important to plan out the signal paths to reduce any issues like signal overlap signal quality loss and interference, from electromagnetic fields.

● Manufacturing capabilities: Ensure that the design is checked to confirm it can be produced using methods and that any unique manufacturing needs, like extra copper plating can be managed.

Copper Base PCB Fabrication Process

In the production of Copper Base PCBs the typical procedure includes these steps:

● Preparing the copper base: The copper substrate is cleaned and prepared for the lamination process. The thickness, dimensions and form of the base are decided according to the designs needs.

● Lamination process; This step involves applying a heat adhesive, to the copper base. Then adding a layer of insulating material usually made of conductive dielectric material on top of it.

● Drilling: Holes are drilled into the substrate for component placement and electrical connections.

● Copper plating: Copper plating involves adding a copper layer onto the insulating surface to form the circuit design. This process can be done times to reach the desired thickness of copper.

● Applying photoresist: The copper surface is coated with a layer of material and then exposed to UV light.

● Etching: The exposed copper is etched away using a chemical solution, leaving behind the desired circuit pattern.

● Solder mask application: A layer of solder mask is applied to protect the circuit from environmental factors and to prevent solder bridging.

● Surface finish: The surface finish is applied to protect the exposed copper traces from oxidation and to ensure proper solderability.

● Electrical testing: The PCB is electrically tested to ensure the correct functionality and performance of the circuit.

These steps may vary slightly depending on the specific manufacturer and the complexities of the design, but they generally provide a good overview of the Copper Base PCB fabrication process.

Copper Base PCB Manufacturing Capabilities of JarnisTech

Therefore, Why  You  should Choose JarnisTech Fabricating Your Copper-base PCB Project

20 Years Experiences Of Copper Cores PCB Manufacturing

Leveraging over two decades of experience in the copper PCB manufacturing industry, JarnisTech has been committed to delivering exceptional services to clients across a diverse range of LED projects. Our extensive expertise extends from the production of copper and aluminum base PCBs to LED PCBs with FR4. We pride ourselves in being well-equipped with an array of premium-grade raw materials to offer comprehensive solutions tailored to meet your specific project requirements.

● Quality Assurance: At our organization, product quality takes precedence over any other aspect. We demonstrate this by adopting a proactive stance in managing our raw material sourcing program, which we do so by fostering strategic partnerships with reputable, globally-recognized suppliers. To further bolster our quality control processes, our dedicated Quality Assurance Department performs comprehensive checks on all raw materials and finished products with a consistent 100% frequency. These measures guarantee that every product leaving our premises meets stringent quality standards, consistent with our commitment to exceeding our customers’ expectations.

● Technical Support Service: At JarnisTech, our Research and Development team comprises skilled professionals who possess domain expertise and extensive experience in LED lighting technology. Our engineers work alongside you throughout the entire project, providing end-to-end support and tailored solutions that suit your unique requirements. Additionally, we offer comprehensive technical assistance to cater to any queries or concerns you may have. If you require any assistance in LED products, we urge you to contact our overseas sales personnel, who are adept at providing you with top-notch service at all times.

JarnisTech Offers These Conveniences as a Copper Core PCB Manufacturer:

● Can achieve wire bonding and flip-chip for COB LED copper core PCBs.

● One-stop copper PCB fabrication and assembly starting from prototypes to production in bulk.

● One-on-one engineering support and design advice throughout the duration of the project.

● Can fabricate copper core PCBs using an hybrid base: copper/FR4, copper/AlN, and copper/PTFE.

● Copper core PCBs can be designed with different shapes based on the requirements of the application.

The Copper core PCB design process is a critical phase that requires expertise in electrical aspects and PCB fabrication feasibility. At JarnisTech, we are committed to delivering solutions that cater to the most complex and demanding needs of our clients. For all your Copper core PCB fabrication requirements, please reach out to us at [email protected], and we will be more than happy to assist you.

Advantages and Disadvantages of Copper Core PCBs

Copper core PCBs offer benefits and disadvangtages, in specific scenarios. Here are some key pros and cons of using Copper Core PCBs:

Advantages

● Thermal Management: Copper based circuit boards effectively dissipate heat from high power elements minimizing the chances of component harm or malfunction caused by overheating.

● Reliable Performance: Copper based circuit boards provide exceptional dependability and longevity making them well suited for challenging tasks that demand top notch performance and consistency.

● Variety: Copper core PCBs come in designs, such as single sided double sided and multilayer options giving designers the flexibility to tailor the board layout to meet specific application needs.

● Machinability: Copper core PCBs are easy to machine and drill, making them a suitable option for customized designs.

● Cost-Effective: Copper core PCBs provide a cost-effective alternative to ceramic substrates, which are typically more expensive.

Disadvantages

● Design Challenges: When dealing with Copper core PCBs it is essential to plan the design to effectively manage thermal issues. This introduces a level of complexity to the design phase. Not all PCB designers have experience working with Copper core PCBs.

● Repairing Hurdles: Fixing Copper core PCBs poses challenges compared to traditional PCBs due, to their intricate design and heat conduction properties.

● Increased Fabrication Time: Copper core PCBs require additional fabrication steps, including the lamination of the copper substrate with FR4 or other materials, which can increase fabrication time and complexity.

● High Thermal Expansion: Copper core PCBs have high thermal expansion, which can cause reliability issues in high-temperature environments if not managed correctly.

Applications of Copper Core PCBs

Copper core PCBs are highly sought after for their thermal control features making them a top choice, for various demanding applications that require high power and reliability such as：

● LED Lighting: Copper core PCBs are commonly used in LED lighting products that require efficient heat dissipation to prevent damage to the LED chip and ensure optimal performance and longevity.

● Automotive: In the industry copper core PCBs are essential for a wide range of uses like engine control modules, powertrain modules and lighting systems. These parts are critical for ensuring that cars meet the standards, for temperature resistance and reliability.

● Power Electronics: In power electronics copper core printed circuit boards (PCBs) find application in devices like inverters, converters and motor drives where effective heat control’s crucial for maintaining top notch performance and dependability.

● Aerospace and Defense: In the aerospace and defense sectors copper core PCBs play a role in applications needing resistance, to high temperatures, good thermal conductivity and dependable performance.

● Medical Devices: like X ray machines CT scanners and MRI machines often rely on copper core PCBs for their reliability.

Copper core PCBs are suitable for applications where thermal management is critical, and high reliability and durability are necessary. By utilizing the benefits of these PCBs engineers can create designs that prioritize efficient heat transfer while reducing the potential, for device malfunctions caused by excessive heat.

Comparison of Copper Base PCBs with Other PCB types

Copper Base PCBs are known for their thermal management abilities when compared to other PCB types. They can efficiently disperse heat making them perfect, for high power uses. Additionally these PCBs boast mechanical strength and rigidity enhancing their long term reliability and durability compared to alternative PCB options.

However, Copper Base PCBs can be more expensive to manufacture due to the cost of the copper substrate, which may limit their use in certain applications Ultimately the selection of PCB type relies on the requirements of the application yet Copper Base PCBs prove beneficial, for high power and high heat scenarios where effective thermal control is essential

Future of Copper Base PCB Technology

The future of Copper Base PCB technology is likely to include advancements in materials, manufacturing, and design that will improve thermal management and increase power densities. This may include the use of new materials such as graphene and nanocarbon composites, as well as the development of more efficient and precise manufacturing processes.

Additionally, new design techniques will be developed to optimize heat dissipation and reduce energy consumption. Overall, the future of Copper Base PCB technology is promising, and it is expected to continue to play a critical role in the development of high-performance electronic devices and systems.

Summary

Copper Core PCB Solutions With JarnisTech

JarnisTech is a renowned manufacturer of custom copper core circuit boards that cater to your specific requirements. We understand that high-power environments mandate circuit boards with superior heat resistance, and we provide tailored solutions to meet these exacting demands.

Our copper core circuit boards are engineered to deliver exceptional high-temperature conductivity, boosting the performance of your devices. We invite you to contact us to explore the benefits of our specialized PCB manufacturing expertise that can deliver on your unique project requirements.

At JarnisTech, we leverage our engineering capabilities to fulfill any fabrication requirement, no matter how complex. We conduct rigorous design rule checks (DRC) and design for manufacture (DFM) tests to guarantee the highest quality results. Our experienced team will collaborate with you to develop a PCB layout that not only meets your specifications but also efficiently utilizes space, streamlines the manufacturing process, and adheres to safety regulations.

Our manufacturing processes are optimized for efficiency and compliance, ensuring that the final product is of the highest quality and delivered within the desired timeframe. In general we offer solutions, for PCB manufacturing focusing on safety cost effectiveness and following the rules.