MCPCB: Metal Core PCB for LED and Thermal Management

MCPCBs, or metal core PCBs, are widely used for LEDs and thermal dissipation applications.

The one-stop PCB manufacturer PCBONLINE presents MCPCBs and a comparison between aluminum and copper metal circuit boards and other PCBs for your reference.

Part 1. What is MCPCB

MCPCB, or metal core PCB, is a printed circuit board that uses copper or aluminum as its substrate material.

An MCPCB consists of a metal core, prepreg/polymer layers, copper circuit layers, and solder masks.

The metal core of an MCPCB is usually aluminum or copper. Iron is rarely used for MCPCBs.

Aluminum PCB is the most common and affordable MCPCB for LEDs. It has 1 to 4 circuit layers.

Copper-base PCB is an MCPCB better than aluminum PCB in thermal dissipation. It has 1 to 8 circuit layers.

From a metal core PCB manufacturer, PCBONLINE, you can also have MCPCBs that use hybrid or inlay materials, such as copper/FR4, copper/ceramic, aluminum/FR4, etc.

Advantages of MCPCB

MCPCB was invented to replace the FR4 PCB for LEDs because metal conducts heat a lot faster than FR4.

Thermal dissipation is the core advantage of MCPCBs. The thermal conductivity of regular MCPCBs is 1W/mK to 9W/mK. While an FR4 PCB has a thermal conductivity of only 0.3W/mK.

Regular MCPCB Has 1 to 2 Layers

For normal MCPCBs, heat conducts from electronic components to the copper layer, prepreg layer, and metal substrate.

We all know that copper and aluminum conduct heat quickly, but the prepreg material conducts heat much more slowly. So the prepreg material determines the thermal conductivity of MCPCBs.

The MCPCB manufacturer PCBONLINE uses the same prepreg material for aluminum and copper MCPCBs. It is a special polymer filled with epoxy resin composed of aluminum oxide and silicon powder. Though its thermal conductivity is better than FR4, it is much poorer than metal.

For this, if a regular MCPCB has multiple PCB layers, the heat conductivity effect will not be very good. So regular MCPCBs are usually designed to have only 1 or 2 PCB layers.

However, for copper MCPCBs, the thermoelectric separation technology provides more possibilities. However, the thermal conductivity of copper MCPCBs from PCBONLINE can reach 398W/mK.

Part 2. Copper MCPCB vs Aluminum PCB

Copper-base PCBs and aluminum PCBs are both widely used MCPCBs for thermal dissipation devices. Which is the best MCPCB option for your design? Please check copper MCPCBs and aluminum PCBs.

Copper MCPCBs

A copper-based MCPCB is also known as a copper-core PCB.

A regular copper-based MCPCB is a 1- or 2-layer metal core PCB. Its thermal conductivity is better than an aluminum PCB in the same stack-up.

However, normal copper base PCBs don't have many advantages over single-sided 1- or 2-layer aluminum PCBs because their price is higher.

However, it becomes another story when you design thermoelectric separation copper MCPCBs.

Thermoelectric separation copper MCPCBs can have up to 8 PCB layers. And the thermal conductivity is the same as copper!

Thermoelectric separation means the circuitry and thermal conductivity are separated. The copper traces conduct electricity, and the prepreg only isolates adjacent copper layers. Heat conducts directly through the copper vias under the components to the copper substrate. Around the copper vias, the resin is filled to isolate the copper vias and the circuit layers.

If you can design the thermoelectric separation copper MCPCB, you don't need to worry about thermal management anymore.

PCBONLINE will fabricate copper MCPCBs using thermoelectric separation technology. Besides, 1- to 8-layer MCPCBs, inlaid copper MCPCBs, and hybrid-laminated MCPCBs are available. If you have problems or don't have a design, PCBONLINE can also provide you with PCB design services.

Aluminum PCBs

An aluminum core PCB can be single-layered, 2-layer with a single component-mounting side, 2-layer with double component-mounting sides, or 4-layer with double component-mounting sides.

The thermal conductivity of aluminum is lower than copper, so compared with single-sided 1- or 2-layer copper base PCBs, single-sided aluminum PCBs conduct heat a little slower.

However, the aluminum PCB price is much lower than copper MCPCBs. From PCBONLINE, you can order bulky aluminum PCBs for only $30/㎡.

For LED lamps, the aluminum PCB is the most cost-effective PCB option.

Copper MCPCBs vs aluminum PCBs

For MCPCBs, there are 1-, 2-, and 4-layer aluminum core PCBs, while there are 1-, 2-, 4-, 6-, and 8-layer copper core PCBs.

The thermal conductivity of regular copper MCPCBs is a little better than aluminum PCBs, and the thermal expansion of copper base PCBs is smaller than that of aluminum PCBs, but the price is higher.

Copper MCPCBs are only single-sided, but aluminum PCBs can be single-sided or double-sided.

However, copper MCPCBs can be designed and fabricated to be thermoelectrically separated. In such cases, the thermal conductivity of copper MCPCBs can reach 398W/mK.

Part 3. MCPCB vs Ceramic PCB vs FR4 PCB

Is MCPCB, FR4 PCB, or ceramic PCB the best for a thermal management project?

MCPCBs are a common PCB choice for devices such as LEDs that require thermal management, but ceramic PCBs may be more effective. Sometimes, FR4 PCBs can also serve thermal dissipation purposes if they are artfully designed.

Please check a comparison among MCPCBs, ceramic PCBs, and FR4 PCBs below.

Besides the above PCBs, PCBs with phase-change substrate materials can also be a choice for thermal dissipation solutions. For example, the hybrid MCPCB below, used for an air conditioning system, has a copper and FR4 phase-change substrate.

MCPCBs provide reliable and cost-effective options for thermal management. Besides MCPCBs, ceramic PCBs may be a better option for high-power devices, especially when the PCB has ICs.

To choose the best PCB for your project, you need to strike a good balance between thermal conductivity, thermal expansion, and budget. But whatever the PCB substrate and requirements of your design are, PCBONLINE can meet your fabrication requirements.

Part 4. Metal Core PCB Manufacturer PCBONLINE

The MCPCB manufacturer PCBONLINE provides one-stop thermal management solutions for power devices.

PCBONLINE fabricates and assembles regular copper MCPCBs, thermoelectric separated PCBs, aluminum PCBs, and phase-change-substrate MCPCBs.

If you don't have a PCB design, the professional engineers from PCBONLINE can design for your project. Besides, PCBONLINE provides value-added services, such as conformal coating, IC programming, mechanical boxes, and box-build assembly for MCPCB assemblies.

Here are reasons why you choose to work with PCBONLINE for MCPCB fabrication:

If you have an MCPCB project that needs one-stop fabrication, please feel free to contact PCBONLINE by email at info@pcbonline.com.

Part 5: Examples of MCPCBs for LEDs and Thermal Management

PCBONLINE has rich experience in providing thermal management MCPCB solutions for our clients around the globe, from PCB design, fabrication, and assembly to end product delivery.

Example 1 - thermoelectric separation copper MCPCB

This is an 8-layer thermoelectric separation copper base PCB. The copper thickness of the inner and outer layers is 12oz. From the cross-section, you can see very even electroplated via copper and layer copper. Our PCB lamination has perfect quality.

Example 2 - aluminum LED metal core PCB

This is a 100W LED metal core PCB designed, fabricated, and assembled by PCBONLINE, including the LED beads. The MCPCB is an aluminum-backed PCB in a rounded shape. The MCPCB assembly has 16 LED beads, and each bead has 4 LED chips.

Example 3 - FR4 and copper hybrid MCPCB

This is a copper-inlay FR4 PCB used for high-power electric car charging stations. It is the adaptor board. In this hybrid MCPCB, the 3oz circuit layers are responsible for small currents and signal conduction, while the copper plates with screws are responsible for large currents and dissipation.

The effective combination of copper plates and FR4 is critical to this MCPCB's success. PCBONLINE has strong PCB manufacturing capabilities and technical experience in electric vehicle electronics.

Conclusion

MCPCBs are a cost-effective PCB option for devices that require good thermal dissipation. Copper MCPCBs have higher thermal conductivity and lower thermal expansion than aluminum PCBs, but they cost more. Besides MCPCBs, you can also consider ceramic PCBs and FR4 PCBs. If you need the design and fabrication of thermal management projects, don't miss the more than 20-year-old source factory PCBONLINE.

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