What Are Aluminum Clad Boards?
Aluminum clad boards (ACBs) are multi-layer composites engineered for high-performance thermal management. Typically composed of a core aluminum alloy (e.g., 3003 or 7072) sandwiched between clad layers (e.g., 4343 or 6061), these boards leverage metallurgical bonding to achieve exceptional heat dissipation, structural rigidity, and corrosion resistance. Unlike monolithic aluminum sheets, ACBs integrate optimized material combinations—such as 4343/3003/4343 or 4343/3003/7072—to balance thermal efficiency (1.5–3.0 W/m·K) and mechanical stability under extreme conditions.
Key Parameters, Cost, and Applications
2.1 Technical Parameters
- Thermal Conductivity: 1.5–3.0 W/m·K, depending on alloy combinations (e.g., 4343/7072 achieves ~2.8 W/m·K).
- Mechanical Strength: Tensile strength ranges from 116–119 MPa, with elongation rates of 32–40% for dynamic load resistance.
- Weight: 30–50% lighter than copper-based alternatives, with a density of 2.7 g/cm³.
2.2 Cost Efficiency
ACBs cost $25–$50/m², roughly 40% cheaper than copper-clad solutions. The hot-rolling production process minimizes waste, while standardized alloys like 3003 reduce raw material expenses.
2.3 Application Environments
- LED Lighting: High-power LED modules requiring uniform heat distribution (e.g., streetlights, automotive headlights).
- Power Electronics: IGBT modules, EV inverters, and solar converters needing <80°C junction temperatures.
- Consumer Electronics: Ultra-thin laptops and 5G.
Aluminum Clad Boards vs. Competing Materials
3.1 ACBs vs. Traditional Aluminum Sheets
Monolithic aluminum sheets (e.g., 6061) offer lower thermal conductivity (1.0–1.5 W/m·K) and are prone to warping under thermal cycling. ACBs’ layered design enhances heat spreading by 60–80%.
3.2 ACBs vs. Copper-Clad Boards
Copper provides higher thermal conductivity (~400 W/m·K) but weighs 3x more. ACBs reduce system weight by 50% while maintaining sufficient heat dissipation for most LED and mid-power applications.
3.3 ACBs vs. Ceramic Substrates
Ceramics (e.g., AlN) excel in ultra-high thermal conductivity (170–200 W/m·K) but are brittle and cost-prohibitive. ACBs offer fracture toughness (elongation >30%) at 1/10th the cost.
Common Challenges & Solutions
4.1 Delamination at High Temperatures
Mismatched thermal expansion between layers can cause separation. Solution: Use alloys with aligned CTE values (e.g., 4343/3003) and optimize hot-rolling parameters to ensure >9% cladding rates.
4.2 Inconsistent Heat Spreading
Poor interfacial bonding creates thermal bottlenecks. Mitigation: Plasma surface treatment improves adhesion, reducing thermal resistance by 15–20%.
4.3 Corrosion in Humid Environments
Moisture ingress degrades aluminum alloys. Workaround: Apply anodized coatings or use 7072 cladding layers, which provide sacrificial corrosion protection.
Why Choose Aluminum Clad Boards for Your Project?
(From sales@huaxingpcba.com)
Q: “Can ACBs handle 100W LED arrays without heatsinks?”
Absolutely! Our 4343/7072 boards achieve 3.0 W/m·K conductivity—ideal for passive cooling. We’ve supplied ACBs for LED streetlights that maintain <75°C at 120W loads, cutting heatsink costs by 70%.Q: “How to ensure ACB durability in automotive vibrations?”
Opt for 3003-core boards with 40% elongation rates. We pre-test samples under 50G shock loads and simulate 10-year vibration cycles to guarantee zero delamination.
Final Note
For lightweight, cost-effective thermal solutions that outperform traditional materials, aluminum clad boards are the smart choice. Questions? Reach us at sales@huaxingpcba.com—let’s power your next innovation.
