1. Design specifications and thermal management strategies
\nLine Layout Principles
\nHeat path optimization:
\nHigh heat generating components (e.g. LED chips, MOSFETs) are laid out directly above the metal base to shorten the heat conduction path.
\nExample: Design copper foil area \u2265 3 times of the chip size under the LED light bead to reduce thermal resistance.
\nElectrical isolation:
\nHigh-voltage area (such as AC\/DC module) insulation thickness \u2265 0.1mm, voltage withstand test needs to pass 3kV\/1min.
\nOver-hole design:
\nAvoid direct drilling on the metal base (damage to the insulating layer), need to use edge connection or non-penetrating thermal over-hole.
\n2. Manufacturing process key points
\nCore process steps
\nPre-treatment of metal substrate:
\nAluminum substrates need to be chemically cleaned (degreasing, micro-etching) and anodized (to increase surface insulation).
\nInsulation coating:
\nHighly thermally conductive adhesive (e.g. Beggs TIF-100) is applied to the metal substrate by screen printing or film pressing.
\nCircuit layer processing:
\nHigh current etching (for thick copper) or graphic plating (for fine circuits) is used.
\nCutting and molding:
\nAluminum substrates are cut with diamond tools to avoid burrs; copper bases require laser cutting or stamping.
\n2.Typical application scenarios and design cases
\nHigh Power LED Lamp Module
\nRequirements: Driving current 5A\/LED, junction temperature <85\u2103, life time >30,000 hours.
\nDesign:
\nSubstrate: 2.0mm aluminum substrate (thermal conductivity 2.2 W\/m-K).
\nCircuit: 3 oz copper foil, LED pads 3mm diameter, 10mm pitch.
\nHeat Dissipation: Thermal Conductive Silicone Grease (0.2mm) laminated on the back + Heat Sink Fins (Surface Area \u2265 50cm\u00b2\/W).
\nElectric Vehicle OBC (On-Board Charger)
\nRequirements: 30kW power, thermal efficiency >90%, vibration resistance.
\nDesign:
\nSubstrate: copper-aluminum composite board (3mm copper layer + 2mm aluminum layer), thermal conductivity 4.5 W\/m-K.
\nCircuit: 6 oz copper foil, copper block (10\u00d710mm) embedded under the MOSFET.
\nStructure: 4-layer metal base stack, connected to liquid cooling system via heat pipes.<\/p>","protected":false},"excerpt":{"rendered":"
1.High Power LED Lamp Module
\n2.Electric Vehicle OBC (On-Board Charger)<\/p>","protected":false},"featured_media":1132,"comment_status":"open","ping_status":"closed","template":"","meta":{"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","theme-transparent-header-meta":"default","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"set","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""}}},"product_brand":[],"product_cat":[45],"product_tag":[],"class_list":{"0":"post-1131","1":"product","2":"type-product","3":"status-publish","4":"has-post-thumbnail","6":"product_cat-pcb","7":"desktop-align-left","8":"tablet-align-left","9":"mobile-align-left","11":"first","12":"instock","13":"shipping-taxable","14":"product-type-simple"},"yoast_head":"\n