Why is Metal Core Printed Circuit Board Widely Used in Led Products?

By | Date posted: | Last updated: September 7, 2024
Metal Core Printed Circuit Board

Printed circuit boards (PCBs) have revolutionized the work of electronic engineers. They play a crucial role in building prototypes for potential designs before products reach the market. Metal core printed circuit boards (MCPCBs) are particularly valuable in electronic devices because metal serves as an excellent conductor of electricity, providing a reliable path for electrical currents between components. MCPCBs are widely used in LED products due to their superior heat dissipation properties. But what exactly are LED products, and what are their applications?

What do we understand by the term LED products?

LED (light-emitting diode) consists of small pixels that emit a bright and clear light. LED is widely used in various products like for light banners that you see on roads, it is used in lights, in making certain parts for automobiles. In short, we have seen a significant transformation in LED past some years. LED is very cost-effective as compared to other conventional products. However, the LEDs can sometimes prove unstable and unreliable; their maximum efficiency cannot be reached if there is no thermal loss. So, to solve this problem in LED products, metal core PCBs are used.

What are Metalcore print circuit boards?

Metalcore PCBs Fr4 was used earlier, but they are used widely because of metal circuit boards’ excellent features. The base material is metal, and the core has the power to redirect the heat that is generated aside from the elements. The metal plate used in it has the power to dissolve the heat. The metal core printed circuit boards are considered a better choice than glass epoxy because of their extraordinary qualities and high conductivity. Since then, MCPCB has been every engineer’s favorite.

The good things about Metal Core Printed Circuit Boards (PCBs)

Improves the material’s reliability: The MCPCBs play a key role in the elements that heat up overly at times. It helps to divert the heat from one side to another where the heat has vanished, which improves the product’s life, making it much more durable.

Prevents overheating: LEDs tend to get overheated very quickly. If a metal core printed circuit board is used, it solves overheating by transferring the energy from one side to another.

can adapt to a high temperature: unlike the fr4 technology, the metal core PCBs can adapt to products with a high temperature, especially it proves to be very useful for LED products.

Lightweight: In metalcore, PCB’s two types of metals are copper or aluminum. Both of them are lightweight and offer great resistance ability. Being lightweight makes the PCB easier to handle and easy to ship between places.

Recyclable: metals are environment- friendly products. They are non-toxic and can be recycled easily. Metalcore PCBs are used in products that require high vibration abilities.

Reasons why metal core PCBs are the best choice for making LED products

Longer shelf and operating life: since it is a well-known fact that LED products emit a lot of heat. The metal core PCBs transfer heat quickly and prevent overheating. Aluminium PCBs are mostly used in these PCBs; they can operate longer than other metals and longer shelf life.

Increase in LED density: since metal core PCB’s have a high conductive ability, there remains ample space for maximum LEDs, which allows producing sufficient light and achieving high performance.

Which is a better choice: aluminum or copper for metal core PCB?

The choice depends on the product you are making and what suits it. The choice is made about the purpose. There are differences between aluminum and copper PCBs; let us delve into that.

  • Copper PCBs have a better ability for heat transfer and dissipation, while aluminum has a lower ability than copper.
  • Aluminum is lighter in weight than copper, making it the best choice if you want a lightweight LED Printed Circuit Boards
  • Copper is always an expensive option, and aluminum comes at a cheaper rate.
  • Mostly aluminum is used for LED due to its varied abilities. Copper is used in very few cases.

Difference between metal core PCB and FR4 PCBs

Plated through-holes: This feature is specifically found in FR4 PCBs. In metalcore, PCB plating through-holes aren’t available for one-layer print circuit boards. Only surface mounting elements are available for metal core PCBs.

Conductivity: FR-4 offers the only 0.3watt of thermal conductivity, which is very low. The thermal conductivity of MCPCB varies from 1 watt to 4 watts, which is a good amount. Metal is said to be a conductor of electricity. That’s why it has higher conductivity.

Thickness: In terms of thickness, FR-4 offers more thickness since it has many layers. Metalcore PCBs are thinner as compared to FR-4.

Thermal relief: Metal core PCBs have more ability to dissipate the heat. In the FR-4 drilling process and deposition has to be carried out to make it dissipate heat.

Solder Mask: In FR-4, the color of the solder mask is red and green, and it is applied on top and at the bottom. In MCPCB, the solder mask comes in white color and is only applied at the top.

Places where metal core PCBs are used

Metal Core PCBs are used in making various products, and it has become every electronic engineer’s favorite. It is widely used in making LED products.

  • It is used in street lights. Since LEDs are used in street lighting, the MCPCB’s allow larger LED’s, which allows in emitting more light.
  • It is also used in automobiles for stereo sets, radios.
  • Generally, it is used in lighting applications since most of them have LEDs in them. Metal Core PCBs are most compatible with LEDs.
  • Things that have high power like high voltage regulators, power supplies. In all these things, MCPCB is used.

By reading the properties of metalcore print circuit boards and the advantage, you must have understood why these are used widely in LED products. However, keep in mind which metal you want to use in your PCB for your design. We think aluminum will be the best option to choose! The metal core PCBs have surely outshined the traditional FR4, and that’s why it is so popular in the market.

At Technotronix, we combine state-of-the-art technology with our advanced engineering to offer Metal Core Printed Circuit Board with highest quality. With over four decades of experience in delivering high quality, on-time, price-competitive products, you can bank on us for your MCPCB requirements. he fact that we have over 4 decades of experience in manufacturing state-of-the-art metal core PCBs and have a huge body of industry knowledge makes us a go-to PCB partner.

To get more insights into the PCB fabrication and PCB assembly services, please explore our PCB fabrication services. Also, you can drop an email to [email protected] or give us a call at 714/630-9200 to solve your queries or to get a quick PCB fabrication quote.

A Comprehensive Guide for Multilayer PCB Fabrication Process!

By | Date posted: | Last updated: January 18, 2023
Multilayer PCB Fabrication

Multilayer PCB Fabrication is a complex process that requires expertise to master. Multilayer PCB assembly is quite a complicated task, there are several factors that affect the costing of Multilayer PCB assembly. But, as we are talking about the process of multilayer PCB Fabrication, here is a quick overview of the many aspects that make up the entire process of multilayer PCB Fabrication:

Checking design for manufacturability (DFM)

Once your PCB design is ready, you would be in a position to send the output files to a fabricator. What the fabricator will do is to make sure that the design works and that it is possible to build the board as per the design provided by you. With this check underway, the design output data will be used to create images. There are different tools that can be used by the fabricator such as:

  • Photoplotter

  • Direct Imaging technique

The fabricator will use either ultraviolet light through a process of photolithography or use a focused laser beam.

Inner layers for Multilayer PCB Fabrication

The inner layers of the PCB are typically made up of FR-4 material. The inner layer laminate is thus created, by bonding copper to the core material. The photoresist material is coated on the copper and one layer image from the PCB CAD data is exposed to the photoresist. The basic principle behind this, is that the exposed areas will harden while the unexposed ones, remain soft and pliant. The areas of unprotected copper can now etched away. Once the etching process is done, the hardened photoresist is removed.

The step now needs to be followed for each layer of the multilayer PCB fab. The next step is a process of thorough inspection through automated systems to ensure that there is no room for error.

Lamination in Multilayer PCB Fabrication

This step involves the use of prepeg, which is a sheet of fiberglass along with epoxy resin. The inner layers are then stacked along with prepeg to ensure there is alignment. The top and bottom prepeg layers are covered with copper foil. Now comes the final step of the lamination process whereby the entire unit is heated and the layers are fused into a circuit board.

Next comes the process of drilling and application of copper on the interior of the drilled holes.

Just as the inner layers were created, it is now time to add the top and bottom circuitry. The circuitry is then plated and covered with tin. It is time now to remove any remaining photoresist as well as etching away of extra copper and finally removing the tin.

Final touches

This step involves applying the solder mask. Post that, the choice of surface finish, silkscreen and markings are applied. A professional PCB fabricator is fully equipped to offer a wide range of surface finishes that the project demands.

Now comes a very important step in the process of multilayer PCB fabrication. This step is that of electrically testing the board. Post this there is a final inspection.

Clearly then the entire process involves a lot of expertise and precision. The litmus test of whether the PCB is built correctly begins at the design stage itself. With the use of proper design tools you can, in turn, ensure proper component placement, correct spacing etc. during fabrication. It is this expertise and precision that in turn results in boards that are:

  • Light weight and small
  • Are high on flexibility
  • Lend themselves to high capacity and speed

Whether you are looking at a board with a few layers or complex boards up to 24 layers, what you will get is complete commitment to quality. In addition, we have some extremely stringent testing protocols that ensure that the boards never let you down!

At Technotronix, we have over 4 decades of experience in multilayer PCB fabrication. You can rely on our PCB design tools that, in turn, lead to that perfect PCB fabrication. An improper design can lead to a wide variety of issues such as imbalance.

Asymmetrical designs, for example, can lead to twisting or bows. It is extremely important, therefore, to go with a partner who understands these issues. Our experienced staff has a robust body of industry knowledge that ensures that you avoid costly mistakes later. Our superior engineering capabilities mean that each board matches your exact requirements and technical specifications. In case if you have any questions, please feel free to contact us via email at [email protected]

PCB Fabrication Process for Type of FR4 Semi Flex PCB!

By | Date posted: | Last updated: April 15, 2021
PCB Fabrication Process

When it comes to PCB fabrication, the importance of flex-rigid PCBs cannot be overstated. The one driving reason for it is the growing trend of miniaturization of products. Besides, with the flexibility and the capability to be 3D assembled, the demand for flexi-rigid PCB is on the rise. However, not all PCB manufacturers are able to cater to the complex flexi rigid printed circuit board fabrication process. Semi-flexi printed circuit boards are manufactured through a process, which brings the thickness of a rigid board down to 0.25mm +/- 0.05mm. In turn, this allows the board to be used in applications, which require bending the boards and fitting them inside casings. The boards could be used in one-time bend installation as well as in multi-bend installations.

Below is an overview of some its properties that make it unique:

Properties of FR4 Semi-Flexible PCB

  • The most important property that lends itself to multiple use is the fact that it is flexible and can adapt to the available space.
  • The fact that its flexibility does not come in the way of its signal transmission, adds to its ubiquitous use.
  • It also lends itself to being light-weight.
  • Typically, semi-flex PCBs are also known for their optimal costs as their fabrication procedure is compatible with the existing manufacturing capabilities.
  • They save time both during the design phase as also during assembly.
  • They are an extremely reliable alternative especially as they avoid many issues including entangling and welding.

PCB Fabrication Procedure

The broad procedure for fabricating FR4 Semi Flex Printed Circuit Boards is as follows:

The process broadly covers the following aspects:

  • Material cutting
  • Dry film coating
  • Automated Optical Inspection
  • Brownization
  • Lamination
  • X-ray inspection
  • Drilling
  • Electroplating
  • Graphics Conversion
  • Etching
  • Silkscreen printing
  • Exposure and development
  • Surface finish
  • Depth-controlled milling
  • Electrical test
  • Quality Control
  • Packaging

What are some of the issue faced and plausible solutions in the PCB fabrication process?

The big issue in fabrication is to ensure accuracy as also tolerance of depth-controlling milling. The important bit is to also ensure that there are no resin cracks or oil peeling that leads to any quality issues. This involves checking for the following aspects during depth-controlling milling procedure:

  • Board thickness
  • Resin content
  • Milling tolerance

Depth Controlled Milling Test A

The thickness milling is performed with the Mapping method to conform to the thickness of 0.25 mm, 0.275 mm and 0.3 mm. Post this the board is subject to testing to see if it can adhere to the 90-degree bending. Typically, if the remaining thickness is at 0.283mm, the glass fiber is deemed to be damaged. It is imperative, therefore, to consider the board thickness, glass fiber thickness as well as the dielectric situation, in carrying out the depth milling.

Depth Controlled Milling Test B

Based on the above it needs to be ensured that the thickness of copper between solder mask and L2 is in the range of 0.188mm to 0.213 mm. Due emphasis also needs to be paid to any warpage that may occur thereby impacting the uniformity of overall thickness.

Depth Controlled Milling Test C

Post the prototyping of the panel, Depth control milling is important to ensure the size is set at 6.3″x10.5″. Post that, mapping point measuring is undertaken to ensure that the vertical and horizontal intervals of 20 mm are maintained.

With a special fabrication method, it is ensured that the tolerance of the deep controlled thickness lies in the range of ±20μm.

At Technotronix, we combine state-of-the-art technology with our advanced engineering to offer you semi flex printed circuit boards of the highest quality. With over four decades of experience in delivering high quality, on-time, price-competitive products, you can bank on us for your PCB requirements. Our Semi-Flexible FR4 Printed Circuit Boards are used across a wide range of industries and are available at the best turnaround times. What this additionally means for you is quick time-to-market which in turn, adds to your competitiveness. The fact that they are priced competitively means that you will be well within your budgets.

To get more insights into the PCB fabrication and PCB assembly services, please explore our PCB fabrication services. Also, you can drop an email to [email protected] or give us a call at 714/630-9200 to solve your queries or to get a quote.

What Is Tenting Via & How It Plays Important Role In PCB Fabrication?

By | Date posted: | Last updated: February 14, 2022
pcb-tenting-vias-fabrication

When it comes to establishing connection patterns between the various layers of a board, vias play an extremely important role. Simply put, vias are holes on the PCB without which the connections cannot be formed and therefore the PCB would not work.

They are often covered with different materials as this helps in the twofold process of:

  • Helping in conducting electric signals
  • Dissipating heat

While this may be thought of as a fairly straight-forward process, the fact is it is quite a specialized process when it comes to PCB fabrication.

Quite often, vias are copper-plated. However it depends on the PCB design whether the holes are covered or exposed. When the via or the hole is fully covered, it is called a masked or a filled via. On the other hand, PCB designers can also use another method called tenting, which is quite popular.

What is tenting via and why is it done in PCB Fabrication?

As its name suggests, tenting via implies creating a tent like shape over the hole. This is done so that the numbers of exposed conductive pads on the PCB are limited.
The process of tenting entails using a solder mask to enclose the opening. Whether or not you should use tenting in the PCB fabrication really depends upon the design of your board.

Below are the benefits and limitations of using tenting in PCB fabrication service:

Benefits of tenting a via

The foremost advantage that tenting vias offers is the protection offered by the solder mask. The tenting creates a barrier that ensures there aren’t any damages to the PCB layers. This is akin to how the solder mask prevents corrosion in the copper traces.

Another advantage of the tenting method is also that the numbers of exposed conductive components are minimized. The exposure of these components can result in corrosion. Tenting also helps in significantly bringing down the possibility of a short on account of the solder bridging. With tenting, you can also rest assured that the paste migration from SMT pads is significantly reduced.

The fact that tenting is a cost-effective method of protecting the vias is an added perk!

Limitations

A major limitation of the tenting process is that with a liquid solder mask, there is always the possibility of breaking of LPI and creating small holes in the tent. In turn, these holes can trap moisture and corrosion can be the natural outcome.

To overcome this limitation, it is important that the vias are left exposed in the prototype stage. That way, any issues can be identified and the traces can be fixed. With covered vias the opportunity to discover these issues is significantly limited.

How to make the decision to tent a via?

Two major aspects go in to decide whether or not you should tent a via. The first, of course is the PCB design and the second is the size of the via.

As a thumb rule, tenting works well with vias of smaller diameters of 12 mil or less. Any via that is above 12 mil in diameter does not lend itself to tenting. If you need to take care of large vias closing it with some kind of fill is a far better alternative.

Tenting is also preferred on account of its lower cost as opposed to mask plugging or epoxy filling. In fact tenting via with a liquid photo-imageable solder mask turns out to be the most cost-effective. However where there are concerns about tenting being loose, epoxy filling is an alternative, even though it comes at a higher cost.

Your PCB fabrication requirements along with tenting via!

With more than 4 decades of experience in PCB Fabrication USA, at TechnoTronix we have the technology and production facility to offer the tenting of vias with the highest degree of accuracy. With our experienced engineers you can rest assured that what you will get is an effective production. Little surprise then that clients across industries rely on us for their PCB fabrication, California requirements. Our ability to deliver, unparalleled quality as well as customer service, is what makes us stand out. Both on-time delivery and price competitive products are our USP. The most important element of our success, however, has been the relationships we have developed with our customers.

If you are looking for full fledged PCB fabrication services from product layout, manufacturing to warehousing and shipping, please explore our PCB fabrication services!