Most metal core PCBs use aluminum as the core, and sometimes copper is also used.

They are used in the following situations:

Copper: Copper is used as a PCB core in special situations such as thermoelectric separation that require extremely high thermal conductivity. Copper is also used for multi-layer, double-sided, multi-layer, and single-layer metal core PCBs. Copper also has higher mechanical strength than aluminum. The problem with copper lies in its weight and cost. It is much heavier than aluminum. Although mechanical strength is its strength, it also makes manufacturing very difficult, so there are few copper core manufacturers.

Aluminum: Aluminum is very commonly used in metal core PCBs. Aluminum has high thermal conductivity (not as high as copper), is lightweight, inexpensive, and easy to manufacture. In addition, it is easy to obtain and has more manufacturers offering it than similar copper products. Some aluminum alloys are also used as metal cores, which are heavier and more expensive but have higher mechanical strength. Many LED PCBs use aluminum core PCBs.

Like most other PCBs, metal core PCBs have a stack consisting of cores, dielectric or insulation layers, and copper or circuit layers. But unlike other PCBs, it mostly has exposed cores made of metals such as aluminum, aluminum alloy, or copper. The thickness of the metal core may vary depending on different requirements, and the thickness of the metal core is mostly between 1 millimeter and 1.6 millimeters.

Usually, these PCBs only have one layer of copper, but there are also options for multiple layers, although there are not many manufacturers of metal core PCBs. Some of the stacks of these PCBs are as follows:

This is the most commonly used type of stacking. It is composed of a single wiring layer, hence more commonly referred to as a single-layer metal core PCB. It is a very simple stack, with the metal core isolated from the signal layer by a dielectric layer.

Its manufacturing cost is low and it is widely used in industrial relays and simple LED lighting solutions.

Thermoelectric separation stack is very similar to single-layer metal core PCB, except that the core is made of copper and the stack allows the core to contact the element body rather than the element pads. The component pads are insulated by dielectric materials to ensure proper electrical isolation and the highest level of thermal efficiency.

This type of PCB is widely used in high-power LEDs. The manufacturing cost of thermoelectric separation PCB is very high, so it is not used for simple LED solutions.

Type 1: Copper dielectric copper dielectric core

Do not confuse it with double-sided metal cores. A double-layer metal core PCB is similar to a single-layer PCB, but with an additional copper layer and insulation layer that can be wired. Due to only one layer of copper being exposed, the component can only be placed on one side. It introduces through holes in metal core PCBs, simplifying wiring and achieving more compact and dense designs.

It is used for audio devices such as power modules and amplifiers.

Type 2: Copper - Dielectric - Core - Dielectric - Copper

Both sides of the double-sided metal core PCB have exposed copper, so components can be placed on both sides of the PCB. Like double-layer PCBs, it can also utilize vias. This stacking reduces the heat dissipation of the circuit board, but allows for more components to be placed on the PCB.

Manufacturing this type of PCB is more difficult than manufacturing FR4 PCBs.

Double sided metal core PCBs are used for many traditional components, such as hard disk drives and uninterruptible power supplies (UPS).

Like double-layer metal core PCBs, multi-layer PCBs have more copper and dielectric layers between the surface copper and the metal core. It is not recommended to manufacture multi-layer metal core PCBs with more than 4 layers (most metal core PCB manufacturers can only manufacture up to 4 layers), as the thermal management of the PCB will be significantly reduced due to the increased spacing and dielectric insulation between components and metal cores. Due to the use of more than 2 layers, blind holes and buried holes can also be used on multi-layer metal core PCBs.

It must be noted that this type of PCB cannot use through-hole components. Multilayer metal core PCB boards are very expensive, and the use of advanced features such as blind holes and buried holes will further increase costs.

Compared to traditional PCBs that use FR4 as the core, copper metal core PCBs have many advantages. Some of them are:

Reduce PCB weight: Metal core PCBs mostly use aluminum as the core, which is a very lightweight material. Compared to FR4 printed circuit boards of similar size, aluminum is much lighter in weight.

Enhanced thermal management: Metal core PCBs, especially copper metal core PCBs with thermoelectric separation, have excellent thermal management. Due to the presence of metal cores, heat is evenly distributed on the PCB board and dissipates faster from the PCB body. This also eliminates the need for thermal paste and heat sinks for the components.

Better durability: Due to the presence of metal cores, the robustness and durability of PCBs are increased.

Recyclable:- The metal core of PCB can be recycled and reused, and even if discarded, it will not cause toxicity to the soil.

Metal core PCBs are widely used due to their excellent thermal management and mechanical strength. Some of its applications include:

LED Lighting: Metal core PCBs are the most widely used in LED solutions. LEDs emit heat during operation. The more current passes through the LED, the more heat it generates. For high-power LEDs, the heat generation is even higher. Therefore, LED metal core PCBs are an ideal choice for LED solutions as they can effectively and quickly dissipate heat. For high-power LEDs, it is more inclined to use thermoelectric separation. Metal core PCBs are widely used in vehicle headlights, floodlights, and high-intensity spotlights (which use thermally and electrically separated metal core PCBs). Commercial light bulbs, flashlights, and streetlights typically use single-layer and double-layer metal core PCBs with aluminum cores.

Power switching: Metal core PCBs are widely used in high-power power switch equipment such as industrial relays. High voltage AC-DC converters and other power equipment typically use metal core PCBs.

Automotive Electronics: Automotive electronics solutions typically operate at extremely high temperatures. Although automotive grade components can withstand more temperature changes, it is best to keep the components at their optimal temperature. ECU or engine control unit is an example. ECU (Engine Control Unit) is usually placed near the vehicle engine, which is one of the largest heat generators in the vehicle. Therefore, the PCB of ECU is usually made of metal core PCB to effectively dissipate heat. Other automotive components such as headlights and taillights also use metal core PCBs.

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